Cavity & Casing Machining
Brightening Your Ideas with Prototypes
We look forward to working hand-in-hand with you. As a prototype expert in cavity & casing, our confidence comes from our hard work and strength.
We focus on providing complete cavity & casing prototypes, expanding our knowledge and experience in this field to provide professional prototype services to many well-known cavity & casing OEMs and suppliers worldwide.
Casing & Cavity Machining - KeSuRapid
From proof of concept design reviews and custom parts system development engineering tests to industry projects, from rapid prototypes to custom prototypes, we support all levels of casing & cavity product development processes.
Machined Metal Parts
We specialize in a variety of casing & cavity prototyping developments and rapid manufacturing technologies, providing CNC machining, 3D printing, vacuum casting, rapid aluminum and alloy machining tooling, low volume CNC processes, and sheet metal processing.
The High Precision Machining - Cavity & Casing rapid prototyping
01. Comprehensive CNC Machining
The best combination of 3-axis, 4-axis, and 5-axis CNC milling machines, equipped with machine tools with a stroke of more than 1 meter, gives us the expertise to machine custom parts flawlessly.
02. Prototype Achieves High Precision
KeSuRapid company provides a variety of optional cost-effective precision solutions. Rapid machining achieves integrated processes in two or more materials.
- CNC manufacturing team of professional engineers and machinists, optimized NC programming and efficient toolpaths.
- 5-axis continuous CNC machining for greater machining accuracy and flexibility.
- We pay attention to every design detail; optical pattern details are machined to a minimum radius of R0.10mm.
- Excellent surface quality with a finished surface finish of Ra (μm) 0.2 and surface tolerance of ±0.025mm.
- Auxiliary EDM machining is necessary to meet the overall machining requirements of the casing & cavity part.
From Small Batch Customization to Pre-Production
We have the ability to provide rapid tooling of both alloy and soft steel and low volume production to deliver your end-use molded parts within 2-5 weeks. We provide cost-effective and rationalized advice from designs, materials, production processes, manufacturability, etc.
Precision Of Casing & Cavity Machining
Applications of Cavity Machining
- Mold Making: Essential for creating molds in injection molding or die casting, where cavities define the shape of the final part.
- Medical Devices: Used to machine intricate parts like heart valve components or prosthetics where precision is critical.
- Aerospace Components: For parts like fuel systems or structural components where weight and strength are critical.
- Automotive Industry: For engine components, transmission parts, or any part requiring internal channels for fluids or cooling systems.
- Electronics: In creating enclosures or parts with specific cavities for fitting components like circuit boards or batteries.
Challenges in Cavity Machining
- Tool Wear: Machining cavities, especially in hard materials, can lead to significant tool wear, requiring frequent tool changes or advanced tool coatings for longevity.
- Chip Evacuation: In deep or complex cavities, removing chips can be challenging, potentially leading to tool breakage or reduced surface quality.
- Heat Dissipation: Heat generated during cutting can affect material properties or tool life, necessitating effective cooling strategies.
- Accuracy and Tolerance: Maintaining tight tolerances in deep or narrow cavities is challenging due to tool deflection or vibration.
Innovations and Techniques
- High-Speed Machining (HSM): Utilizes high spindle speeds and feed rates to reduce heat, improve surface finish, and increase tool life.
- Electrical Discharge Machining (EDM): For materials where traditional cutting is difficult, EDM can be used to create cavities with high precision.
- Use of 5-Axis CNC Machines: These allow for more complex cavity shapes by moving the workpiece in multiple directions relative to the tool.
- Simulation Software: Advanced CAM software helps in simulating the machining process to predict issues like tool collisions or inefficient paths before actual machining.
Comparison of Cavity Machining Techniques
| Technique | Best For | Advantages | Challenges |
|---|---|---|---|
| CNC Milling | Complex geometries, high precision | High accuracy, versatility | Tool wear, chip evacuation |
| EDM | Hard materials, intricate details | No mechanical stress, precise control | Slower process, surface finish |
| HSM | High surface finish, productivity | Reduces heat, improves tool life | Requires high-speed equipment |
Frequently Asked Questions (FAQ)
- What is the lead time for a cavity prototype?
- Lead times can vary based on complexity; typically, we can deliver in 2-5 weeks for rapid tooling and prototypes.
- Can you handle very small tolerances in cavity machining?
- Yes, we can achieve tolerances as tight as ±0.025mm with our precision equipment and processes.
- What materials can you machine for cavities?
- We machine a variety of materials including aluminum, steel, titanium, metal alloy and various plastics, depending on your project's needs.
- How do you manage heat in deep cavity machining?
- We use advanced cooling techniques like high-pressure coolant systems to manage heat effectively during the machining process.
- What's the benefit of using 5-axis CNC for cavity machining?
- 5-axis CNC machining allows for machining complex shapes from multiple angles in a single setup, increasing precision and reducing production time.