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CNC Titanium TI6AL4V Milled Parts

Project Overview:

Manufacturing Material: Grade 5 Titanium Alloy TI6AL4V
Manufacturing Process: CNC Machining, Turning, Boring, Wire Cutting
Surface Finishing: Beadblasting, Brushing, PVD Coating, Laser Engraving
Quantity: 100 Units
Lead Time: 20 Days

The customer was a Singapore company specialized in designing luxury products featuring the style of high quality, elegancy and durability. To get top quality, lightweight and durability for this Pen, customer changed the aluminum or stainless steel to titanium alloy TI6AL4V for its properties of high strength-to-density ratio and better corrosion resistance. Moreover, we offered a solution to the assembly issue found by prototype testing.
Project Challenges:

1. Titanium alloy had fairly low material thermal conductivity that probably resulted in burning or chip adhesion to cutting tool during its milling.

2. Titanium alloy had less stiffness than many other metals, which led to the risk of distortion and cutting tool jarring during milling this metal.

3. The seamless alignment between the Cap and Housing of this Pen was the key challenge that the prototype testing delivered this point.
  CNC Titanium Milling

Aluminum Milled Prototype   Rapid Aluminum Prototype   Prototyping to Production Step By Step:

Firstly, an aluminum prototype was CNC milled to verify appearance and seamless alignment between Cap and Housing, the milled aluminum prototype delivered the feasibility of seamless alignment, then a titanium prototype was milled for final testing before volume production.
Rapid Titanium PrototypeThe above mentioned challenges occurred for titanium milled prototypes, especially the effective seamless alignment was hard to achieve though the aluminum prototype didn't have this issue. Then our engineer offered a solution of slightly revising the Cap and Housing's design.
Titanium Milled PrototypeOne more titanium prototype was milled to test how the solution worked, and the slightly revised Cap and Housing delivered an excellent seamless alignment, then customer proceeded with the low volume production.
CNC Titanium Milled PartsThe challenges occurred and solved at titanium prototype stage acted as a reliable instruction for the low volume production that went on smoothly and efficiently, the low volume CNC milled parts had better quality.
Titanium PVD Coated30 units were PVD coated in black color and 70 units were sanded and brushed. The thin PVD coating delivered not only the color decoration also the strong hardness and abrasion resistance for the parts.
CNC Titanium Machined PartsThe finished titanium Pens. Each Pen went through strict quality inspection in appearance, shape and fitting, the substandard ones were sorted out for repair or remake, quality inspection sheet was provided as per request.
CNC Titanium MachiningTitanium alloy was widely used in aerospace, military, defence, healthcare for its two material properties of high strength-to-density ratio and great corrosion resistance. Being different to milling other metals, milling titanium alloy had more requirements for heat dissipation and milling system.