Case Study

• Powder Metallurgy vs. Milling – A Game-Changer That Pays for Itself in One Year!

  In the fast-paced world of precision CNC parts manufacturing, efficiency drives success. Recently, a valued client approached us with a straightforward yet critical request: custom rectangular flat bars requiring two through-drilled round holes, surface engraving for identification on one side, and...
• Revolutionizing Bushing Production with Cost-Smashing Powder Metallurgy

  Recently, a client of mechanical assemblies for machinery applications contact us for a custom iron square tube bushings to serve as spacers for elevating component thickness. Each bushing measured 10.0 mm x 10.0 mm in cross-section (length and width), 10.0 mm in height, and 1.0 mm wall thickne...
• Enhancing Adhesive Bonding in Cylindrical Stainless Steel Parts

  The client, a manufacturer in the automotive assembly sector, required a batch of cylindrical stainless steel CNC machining parts with a central blind hole. These parts were integral to a sub-assembly where epoxy adhesive was used to bond them to mating components. During the initial inquiry and quo...
• Fixing Misaligned Holes in a Steel Part

  A client designed a low-carbon steel CNC machining part measuring 1500mm long, 19.05mm wide, and 38.1mm high. This door support guide component required five equally spaced countersunk holes to be drilled along the 19.05mm wide face, centered left to right. During first article inspection,...
• Design Challenges and Improvements for Threaded Component Assembly

  In a recent project, a client specified a design for a CNC machining component featuring an M22x2.0 external thread with a thread length of only 3.0mm, equals approximately 1.5 thread turns. The thread base connects to a larger outer diameter, and initially lacked a thread relief (runout) groov...
• Switch to Stamping Dies: Boosting Efficiency or Bust?

  Building on the positive reception of our previous analysis regarding manufacturing processes (see Apporo CNC Analysis: Fine Blanking Press Can Save 90% of Manufacturing Cost), Apporo Industries is now exploring the shift from laser cutting or NCT (Numerical Control Turret Punching) production...
• Rust Formation in Threaded Blind Holes Post-Galvanization

  The Quality Control (QC) team at Apporo Industries identified an issue with CNC milling machined parts returned from a galvanizing supplier. Specifically, the edges of the threaded blind holes exhibited yellow rust spots. These blind holes, which do not pass through the entire part, were likely not...
• Post-Cutting Nib Removal on Precision Flat Washer Parts

  We encountered an issue with precision flat washer parts after cutting operations using laser cutting, where our quality team reported that both the inner and outer diameters had residual sharp nibs.   Cutting Nib on Precision Flat Washer Parts     These nibs, common in proc...
• Addressing Thread Burr Issues in External Thread Production

  A customer raised a significant concern regarding external threads on a CNC machined part specified as 3 7/8-16 UN-2A, pinpointing the presence of burrs along the threads, as evidenced by the attached images. Although the part passed the ring gauge test, which focuses on thread dimensions and form,...
• Analysis of Rust Formation on Motor Plate

  An issue of rust formation on a motor plate component, which was deemed non-compliant by a customer after delivery. The motor plate, made of carbon steel, was processed through CNC milling, then oiled, properly sealed for packaging before being shipped via sea freight. Upon inspection by the custome...
• Unveiling the True Hardness: The Right Way to Measure Tubular Components

  In the precision manufacturing industry, ensuring the quality of materials through accurate testing is crucial. This case study examines a situation where a customer reported that the surface hardness of a CNC machined tubular component did not meet the required standards due to incorrect testing me...
• Beware the Silent Saboteur: Tumbling Finishing Might Be Undermining Your Work!

  Tumbling, also known as vibratory finishing, is frequently used in the post-processing of CNC machined parts to remove sharp edges and burrs. However, the narrow groove edges might have been deformed due to the impact from tumbling, causing the groove width to shrink and making it impossible to asse...