CNC Machining:Thin-Wall Machining Solutions

Precision deformation control for aluminum alloy components with wall thickness down to 0.3mm
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What Is CNC thin-wall machining?

CNC thin-wall machining is a process where CNC machines perform high-precision cutting on metal/non-metal parts with wall thickness ≤1mm. The core challenges lie in overcoming three main issues: weak rigidity, susceptibility to deformation, and sensitivity to vibration. To achieve micron-level accuracy (±0.02mm), it requires a combination of material mechanics, dynamics, and thermal management technologies.

Rapid-Model offer high-precision custom machining for thin-walled parts, specializing in micro thin-walled components and complex curved surface machining, with a tolerance control of ±0.01mm.
Our capabilities extend to aerospace-grade large cylindrical parts (φ3.5m) and ring-shaped components, with deformation less than 0.05mm/m.
For deep cavity parts and difficult-to-machine materials such as titanium alloys, we employ multi-axis linkage combined with adaptive toolpath vibration suppression.
Additionally, vacuum fixtures and online compensation technology ensure consistent mass production quality, validated through over 50 cases including aerospace fuel tanks and precision sensor brackets.

About CNC machining
CNC machining center

CNC thin-wall machining Services

The thin-walled parts machined by Rapid Model always meet your specific requirements and industry standards.

Precision CNC Milling

CNC Milling services

High-precision 3-5 axis milling, with tolerances as low as ±0.005mm, meets your specific requirements for precision parts. It is the ideal choice for aerospace and medical components.

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CNC Turning

CNC Turning services

We offer customized thin-wall turning services with 15 years of industry experience and advanced lathes, providing your thin-walled parts with strong market competitiveness.

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precision machining

Precision machining services

Our precision machining services use advanced technology to meet the tolerance requirements of various industries. Unmatched accuracy and quality ensure high-performance parts.

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The Thin-Wall Machining Challenge

Deformation control in aluminum alloy components requires specialized expertise and technology

Thermal deformation in machining

Thermal Deformation

Heat generation during machining causes uneven thermal expansion in thin-wall structures, leading to dimensional inaccuracies exceeding 0.2mm in critical aerospace components.

Vibration issues

Chatter & Vibration

Low structural rigidity results in harmonic vibrations that cause surface finish defects, tool breakage, and dimensional inaccuracies up to 0.15mm in automotive applications.

Residual stress

Residual Stress

Material stresses introduced during casting or forging cause warping when released during machining, leading to post-machining deformation exceeding 0.3mm in medical device components.

Our Deformation Control Methodology

Proven solutions developed over 15 years of precision machining experience

Thermal Management

Advanced cryogenic cooling and minimum quantity lubrication systems maintain thermal stability within ±1°C~2°C

Vibration Control

Active damping systems reduce vibration amplitudes by 85% compared to conventional setups

Multi-Stage Machining

Stress-relieving intermediate processes minimize cumulative deformation to under 0.05mm

Adaptive Machining

Real-time compensation algorithms adjust toolpaths based on in-process measurements

Technical Specifications

Precision machining capabilities for demanding applications

Dimensional Capabilities

  • Minimum wall thickness: 0.3mm
  • Positional tolerance: ±0.01mm
  • Flatness: 0.015mm/m
  • Surface roughness: Ra 0.2μm

Equipment Specifications

  • 5-axis machining centers with 20,000 RPM spindles
  • Linear motor drives with 0.1μm resolution
  • In-process measurement with 0.5μm accuracy
  • Ambient Temperature for Thermal Stability (20°C ±1°)

Material Expertise

  • Aluminum 6061-T6, 7075-T651
  • Al-Li alloys (2099, 2195)
  • Cast alloys (A356, A380)
  • High-silicon content alloys

Optimized Machining Process

Our 8-step methodology for deformation control

1

Material Analysis

Residual stress mapping and microstructure analysis

2

Stress Relief

Thermal stabilization before machining

3

Fixturing Design

Low-stress custom workholding solutions

4

Rough Machining

High-efficiency material removal

5

Intermediate Stress Relief

Vibration stress relief treatment

6

Semi-Finishing

Precision machining with deformation allowance

7

Final Stress Equalization

Cryogenic treatment for stress stabilization

8

Finishing

Adaptive machining to final dimensions

Industry Case Studies

Advanced equipment and flexible material options enable us to serve a wide range of industries.

Aerospace parts

Aerospace

Satellite structural components: Reduced deformation from 0.25mm to 0.04mm

Medical device parts

Medical Devices

Surgical instrument housings: Achieved 0.02mm flatness on 0.5mm walls

Automotive parts

Automotive

EV battery enclosures: Reduced scrap rate from 18% to 2.3%

Electronic parts

Electronics

Heat sink arrays: Maintained 0.1mm tolerance on 0.3mm fins

Client Testimonials

What industry leaders say about our solutions

"Rapid Model's deformation control methodology reduced our aerospace component rejection rate by 92%, saving over $450,000 annually in rework costs."

Michael Rodriguez

Director of Manufacturing, Aerospace Solutions Inc.

"Their multi-stage machining process enabled us to achieve the impossible - 0.4mm wall thickness with ±0.02mm tolerance for our medical imaging devices."

Dr. Sarah Johnson

CTO, MedTech Innovations

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