Aerospace & Defense CNC Machining Services

Challenge: Tier-1 prime needed a lightweight, vibration-isolated antenna mount with thin-wall pocketing and tight position tolerance between the RF interface bore pattern and the airframe mounting datum. Prior supplier produced parts that passed dimensional inspection but failed installation fit-up due to residual stress distortion.

Approach: Re-toleranced the datum reference frame during DFM review, switched stock from plate to forged billet to reduce residual stress, fixtured on a 5-axis Haas with soft jaws machined from the part model, and added an intermediate stress-relief between roughing and finishing operations. Full AS9102 Rev C FAI with CMM Form 3 against the ballooned drawing.

Outcome: 100% first-pass acceptance at customer source inspection across 40 units. Installation fit-up issue eliminated. Program extended to follow-on lot of 120 units under blanket PO.

Challenge: Defense OEM transitioning from prototype to production needed dimensional consistency across scheduled releases over an 18-month period. Critical concern was lot-to-lot variation on the rail profile, which had to interchange with any mount conforming to MIL-STD-1913.

Approach: Locked the prototype CNC program and setup sheet as the production baseline. Each release runs the same probe-verified setup, same tool list, and the same CMM cycle on the Chien Wei CWB-450-CNC. SPC sampling on the rail profile generated Cpk > 1.67 on the critical-to-quality features.

Outcome: Zero non-conformances across four production releases. Customer eliminated incoming inspection on the part number after the third release based on documented process capability.

Challenge: Aerospace subtier needed a small lot of high-temperature bushings with a tight ID tolerance and a passivation special-process callout. Two prior shops had quoted but declined due to material handling and process-flow-down requirements.

Approach: Sourced certified Inconel 718 bar with mill test report tied to heat and lot. Live-tool turned on the Chien Wei CWB-450-CNC with carbide tooling rated for nickel-superalloy work and a controlled feed-per-rev to manage work hardening. Routed passivation to an approved processor and verified on receipt against the special-process callout on AS9102 Form 2.

Outcome: FAI accepted on first submission. Material certs, special-process certs, and CoC delivered in customer-template format. Customer added Olympus to approved-supplier list for follow-on superalloy work.