1. The first challenge was the heat dissipation since its fairly low material thermal conductivity, which resulted in workpiece burning or chip adhesion to cutting tool if poor heat dissipation during milling titanium.
2. Titanium alloy had less stiffness than many other metals such as steel and aluminum, this led to the more risk of workpiece distortion and cutting tool jarring during titanium milling if unstable milling system.
3. The seamless alignment between Pen Cap and Housing was the key challenge for this project. A solution of slightly revising the inside geomety for efficient seamless alignment was offered from us.
Prototyping to Production Step By Step:
First of all, an aluminum prototype was CNC milled to verify the Pen's appearance and seamless alignment between Housing and Cap, the aluminum prototype delivered effectiveness of the seamless alignment, then a titanium prototype was followed before the production.