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CNC Titanium TI6AL4V Milled Parts

Project Overview:

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

The customer was a Singapore company specializing in designing the products featuring the style of quality, elegancy and durability. To get better quality, lightweight and durability for this Pen, customer changed aluminum or stainless steel to grade 5 titanium alloy TI6AL4V for its properties of high strength-to-density ratio and better corrosion resistance.
Project Challenges:

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

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

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 milled to verify appearance and the seamless alignment, the aluminum prototype delivered the feasibility of seamless alignment, then two titanium prototypes were followed for the final testing.
Rapid Titanium PrototypeThe titanium prototypes exposed difficulty of seamless alignment though the aluminum prototype was fine for this requirement. 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 definite instruction for the low volume production that went on smoothly and efficiently, had the low volume milled parts at better quality.
Titanium PVD Coated30 units were PVD coated in black color and 70 units were brushed. The PVD coating finishing delivered 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 MachiningBeing different to milling the other common metals, milling titanium alloy had more requirements for the heat dissipation and milling stability.