Case Studies

Real projects demonstrating our precision manufacturing capabilities across aerospace, medical, and industrial applications.

Aerospace & DefenceUSA

Aerospace Engine Mount Bracket — 5-Axis CNC Machining

Confidential Tier 1 Aerospace Supplier

Challenge

A leading aerospace Tier 1 supplier required a complex 5-axis machined engine mount bracket for a next-generation commercial aircraft. The part featured thin-wall sections (0.8mm), tight positional tolerances (±0.01mm), and required full material traceability from billet to finished part.

Solution

materialAluminium 7075-T7351 (stress-relieved)

process5-axis DMG MORI DMU 80, single setup

cycle Time4.5 hours per part

inspectionZeiss CMM full dimensional report (120+ points)

finishAnodize Type II per MIL-A-8625, class 2

Results

First article passed on first submission (100% DPPM)
Positional tolerance achieved: ±0.008mm (exceeding ±0.01mm)
4,800 parts delivered over 18-month contract
99.2% on-time delivery rate
23% cost reduction through DFM optimisation in year 2

"PrecisionIndParts delivered exceptional quality on a critical safety part. Their DFM feedback saved us significant tooling costs and the first article passed first time — unprecedented in our experience."

— Senior Buyer, Aerospace Tier 1 Supplier

Medical DevicesGermany

Minimally Invasive Surgical Instrument — 14-Component Assembly

Medical Device OEM

Challenge

A German medical device company needed a complex multi-component surgical instrument for minimally invasive surgery. The assembly included 14 precisely machined components with sliding fits requiring ±0.005mm clearance, 316L stainless steel, and full FDA-compliant traceability.

Solution

materialStainless steel 316L, electropolished

processSwiss-type CNC turning + 5-axis milling

assemblyClean room class 7, ultrasonic cleaned

inspectionVision system + air gauging for internal diameters

packagingSterile pouch with batch trace code

Results

120-piece first article, 100% dimensional compliance
Internal bore tolerance: +0.003mm over 85mm length
15,000 units delivered across 3 product variants
100% lot acceptance rate for 18 consecutive shipments
ISO 13485 compliant documentation with every lot

"The precision and consistency of their machining is exceptional. Every component is identical, which is critical for our surgical instruments. Their documentation is always complete and on time."

— Director of Operations, Medical Device OEM

Industrial AutomationUK

High-Load Helical Gear Set — 15,000 Nm Gearbox

Industrial Gearbox Manufacturer

Challenge

A UK-based gearbox manufacturer required a matched set of helical gears for a high-torque industrial gearbox rated at 15,000 Nm. The gear pair needed AGMA class 10 precision, profile crowning, and case-hardened teeth for extended fatigue life.

Solution

material8620H case-hardening steel

processCNC hobbing + CBN gear grinding

heat TreatCarburise 1.2mm case depth, 58-62 HRC

inspectionIn-volute profile measurement, AGMA 2015

certificationsMaterial certs, heat treat charts, runout report

Results

AGMA class 11 achieved (exceeding class 10 requirement)
Gear noise measured at 68 dB(A) — 6 dB below specification
Matched pairs marked for assembly, runout within 0.012mm
50 sets delivered, 100% acceptance rate
Ongoing annual contract with blanket PO

"The gear quality we receive from PrecisionIndParts consistently exceeds our expectations. Their technical team understood our application immediately and recommended the optimal tooth profile modifications. A true engineering partner."

— Chief Engineer, Industrial Gearbox Manufacturer