Project Overview

This project involved manufacturing a structural assembly for a precision measurement system using high-strength 7xxx series aluminum alloy.

The assembly weighs approximately 4 kg and serves as a critical structural component of the equipment. Several key features required tolerances as tight as ±0.005 mm, while maintaining long-term dimensional stability.

Over a development period of seven months, our team completed and validated 26 assemblies, gradually establishing a stable and repeatable manufacturing process.

The Challenge

For this type of product, achieving dimensional accuracy is only part of the challenge.

The assembly combines precision machining, welding, heat treatment, and final finishing operations. Residual stress generated during these processes can lead to distortion and dimensional movement.

At micron-level tolerances, even extremely small deformation caused by residual stress or gravity can affect final performance.

The objective was not only to minimize deformation, but also to ensure that any dimensional change remained predictable and controllable.

Manufacturing Strategy

To achieve the required stability, a carefully controlled process was implemented:

5-Axis Precision Machining

Complex geometries and critical interfaces were machined using 5-axis CNC equipment to maintain geometric accuracy and balanced material removal.

Precision Welding

Welding procedures, fixture design, and heat input were carefully controlled to reduce distortion and maintain structural integrity.

Post-Weld Aging Treatment

A dedicated aging process was applied after welding to release residual stress and stabilize the material before final machining.

Finish Machining

Final machining operations were performed only after stress relief to ensure critical dimensions were generated under stable conditions.

CMM Inspection

All critical dimensions were verified using Coordinate Measuring Machine (CMM) inspection to ensure dimensional accuracy and consistency.

Results

Through continuous process optimization and validation, the project successfully evolved from prototype development to stable production.

Key results included:

• Tolerances maintained up to ±0.005 mm

• Controlled and predictable deformation behavior

• Improved dimensional stability after welding and heat treatment

• Consistent quality across 26 completed assemblies

• Full compliance with customer technical requirements

Conclusion

This project demonstrates that precision manufacturing is not only about machining accuracy.

True precision requires controlling residual stress, managing distortion, and ensuring long-term dimensional stability.

By combining 5-axis machining, precision welding, post-weld aging treatment, and rigorous inspection, SY Precision successfully delivered a high-performance structural assembly capable of meeting demanding measurement equipment requirements.