Method	Key operation points	Accuracy improvement effect	Implementation suggestions
1. Unified benchmark design method	Unify the design and processing benchmarks with the inspection benchmarks Use process bosses/reference holes Avoid benchmark conversion errors	Reduce cumulative error (up to ±0.005mm)	Planning the benchmark system at the CAD stage
2. Multi-process collaborative strategy	Separation of rough/finishing machining Reserve aging deformation allowance Stress release before finishing (vibration aging/heat treatment)	Control deformation error (Flatness improvement ≥30%)	Arrange intermediate inspection processes
3. Flexible tooling optimization	Use modular combination fixtures Apply vacuum adsorption fixtures Customize 3D printing conformal supports	Solve thin wall deformation (positioning accuracy ≤ 0.01mm)	Low stress clamping solutions are preferred
4. Intelligent tool management	Dynamic compensation of tool wear (RFID tracking) Adopting micro-lubrication technology (MQL) Special profiling tool design	Guarantee feature consistency (surface roughness Ra≤0.8μm)	Building a tool life prediction model

Analysis Of Part Structure And Processing Difficulties

Customized CNC machining is the key to achieving high precision of complex brackets. Its structural characteristics and processing requirements bring significant challenges:

1. Complex geometric structure: multi-layer hollowing and grooves

(1) Structural features:In order to meet the integration of lightweight, high stiffness, heat dissipation and other functions, brackets often adopt three-dimensional complex designs, including multi-layer internal cavities, deep grooves, thin-walled areas and special-shaped surfaces. The topological optimization results often present irregular organic shapes.

(2) Processing difficulties:

• Limited tool accessibility:Deep cavities, small corners, and internal structures require special customized tools (such as extended necks and ball-end tools), which are prone to interference and increase the number of tool changes.
• Thin walls are prone to deformation/chatter:Cutting forces during processing can easily cause elastic deformation, vibration, and even cracking of thin-walled areas, seriously affecting dimensional accuracy and surface finish.
• Complex programming:Processing complex spatial features requires high-level multi-axis (especially five-axis) linkage programming to ensure accurate collision-free paths, and calculation and debugging are difficult.

2. Multi-faceted machining: High-precision positioning and repeatability challenges

(1) Structural features:The bracket needs to process high-precision features (such as mounting surfaces and hole systems) in multiple spatial directions, and there are strict relative position tolerances (parallelism, verticality, position, etc.) between each feature.

(2) Machining difficulties:

• Multiple clamping error accumulation:Complex structures often require multiple clamping to complete, and the tiny errors (datum conversion, fixture error) introduced by each flip positioning will accumulate, threatening the overall accuracy and the relationship between features.
• Difficulty in establishing and transferring datums:Ensuring that the process datum and the design datum correspond accurately during multiple clamping is the core challenge, which relies on high-precision fixtures and strict control.
• Strict repeat positioning accuracy:Mass production requiresfixtures to ensure micron-level repeat positioning accuracy, which places extremely high demands on fixture manufacturing and maintenance.
• Five-axis coordinate system calibration error:Any deviation in the rotation axis position calibration (turntable center, swing axis intersection) directly leads to machining errors.
  

3. Matching materials and cutting processes: ensuring durability and dimensional stability

(1) Structural features:Functional requirements (strength, corrosion resistance, light weight) determine the diversity of materials (such asaluminum alloy, titanium alloy, stainless steel, high-temperature alloy, engineering plastics), and their processing characteristics are very different.

(2) Processing difficulties:

Material processability differences:

• Difficult-to-process materials (titanium alloy, high-temperature alloy):large cutting force, high temperature, fast tool wear, low speed and small cutting depth with high-performance tools (coated carbide, CBN) and sufficient cooling, high efficiency and low cost.
• Soft/viscous materials (aluminum alloy, plastic):prone to built-up edge and burrs, requiring sharp tools and optimized chip removal cooling.
• Residual stress and deformation:The initial stress of the blank and the material removal during processing break the stress balance, especially the thin-walled/asymmetric structure is prone to deformation and warping after processing or during aging.
• Thermal deformation control:Cutting heat causes local expansion (especially materials with poor thermal conductivity), affecting the finishing size and shape, relying on efficient and uniform cooling.}
• Long-term dimensional stability:The process (parameters, cooling) and post-processing (stress relief,surface treatment) need to be strictly controlled to minimize residual stress and ensure dimensional stability during service life.

The structural complexity of complex brackets (thin-wall hollowing, multi-faceted special-shaped features) directly leads to poor processing accessibility, easy deformation and difficult programming; the core challenge of multi-faceted high-precision requirements is to overcome the accumulation of multiple clamping errors; and the matching of material properties and processes is related to tool life, processing deformation control and the long-term reliability of the final parts. These are the key breakthrough points for improving precision.

LS's Custom CNC Machining Service Advantages

As LS engineers, we are proud of the advantages of our customCNC machining services:

1. Efficient and transparent, one-click start:We provide an online platform for quick upload of drawings and instant quotes, so that you can always understand theCNC machining price, achieve efficient communication and a completely transparent onlineCNC machining service process.
2. Precision manufacturing, no fear of complexity:With advancedmulti-axis CNC machine tooltechnology, we focus oncustom CNC machiningand manufacturing, and can accurately and efficiently complete the processing of complex geometric shapes and high-precision holes, slots and other features.

1. Flexible response, unlimited quantity:We provide extremely flexible production batch management, perfectly supporting the smooth transition from small batch prototyping to large-scale production, fully meeting your diverse project needs.
2. Consistent quality, stable and reliable:We implement a strict quality control system to ensure that each batch of parts delivered has excellent consistency and stable high performance, to protect your products.

Industry application background

The industry application background can be summarized into the following core aspects:

1. Core function: key support and precision guidance

Complex structural parts (such as brackets, bases, connecting arms, etc.) are the "skeleton" and "joints" of mechanical automation equipment.

They play the key role of connecting various functional modules, supporting core moving parts (such as motors, spindles, slides), and providing precision guidance for moving parts.

Its own geometric accuracy, dimensional stability, rigidity and dynamic characteristics directly determine the positioning accuracy, motion stability and final performance of the entire equipment.

2. Industry cornerstone: the premise of reliability and stability

In the fields of precision automation such asrobots, high-endCNC machine tools, semiconductor manufacturing equipment, precision testing instruments, medical equipment, optical instruments, etc., the reliable operation and long-term stability of equipment are the lifeline.

As the basic structure of the equipment, the complex bracket will be amplified by its tiny deformation, vibration or installation error through the system, resulting in:

• The equipment accuracy is reduced and cannot meet the process requirements (such as inaccurate repeated positioning of robots and out-of-tolerance processing of machine tools).
• Abnormal wear of key components (such as bearings and guide rails) shortens the life of the equipment.
• Equipment runs unstably, generates vibration or noise.
• Assembly is difficult or requires repeated debugging, affecting production efficiency and cost.

Therefore, high-precision, high-rigidity customized brackets are the fundamental prerequisite for ensuring that the equipment achieves the designed performance, achieves precision assembly and operates stably and reliably for a long time.

3. Wide and critical application areas

1. Industrial robots:Robot bases, arm connectors, end effector brackets, etc. require extremely high rigidity and precision to ensure motion trajectory accuracy, repeated positioning accuracy and load capacity.
2. Industrial automation:Conveyor line brackets, precision positioning platform bases, assembly fixture bodies, sensor brackets, etc. in automated production lines directly affect production rhythm, product consistency and yield rate.
3. Electronic manufacturing:SMT placement machine frames, PCBdrilling/depaneling machine bases, wafer handling/detection equipment brackets, etc., have strict requirements on thermal stability, micron-level accuracy and cleanliness.
4. Semiconductor equipment:Precision motion platforms and cavity support structures in lithography machines, etchers, and thin film deposition equipment require nanometer-level precision and extremely high stability.
5. Medical equipment:Imaging equipment (CT/MRI) stand, surgical robot arm, precision detection instrument stand, etc., are about diagnostic accuracy and surgery protection.
6. Aerospace:Test equipment tooling, aerial structural hardware, satellite component stand, etc., require light weight, high strength, and environmental stability of dimensions in severe environments.

This industry application context stresses the non-replacement nature of complex structural hardware as important supporting and guide parts in advanced-level mechanical automation machinery.A. Industry Application Background. Its precision directly affects equipment performance, reliability, and stability, and serves as the basis for precision assembly and high-performance operation. They are widely utilized in large-scale industries such as robotics, industrial automation, electronic production, semiconductors, medical, aerospace, etc. requiring very high accuracy and dependability.As new technology upgrading and emerging industry develop, they are faced with higher accuracy, more advanced performance, and more customization. The key solution to meet the manufacturing challenge of such high-precision complex connecting brackets is customized CNC machining.

Case Study: Helping Automation Equipment Industry Enterprises Overcome the Challenge of Complex Connecting Brackets

Hi, I'm Gloria, one of the engineers from LS. I'd like to present a recent, highly typical project case which fully demonstrates how we support customers to conquer the manufacturing challenges of high-precision and complex components.

Customer Challenge:

One of the prominent automation equipment manufacturers approached us with a request to design a complex connecting bracket. This item is the core connector of the most critical moving parts of the machine and has very stringent requirements: it has multiple machined surfaces and complex grooves that have to be precisely matched. The slightest dimension difference can cause compromised assembly, or worse, of the entire machine or unsatisfactory performance, which consequently affects the functionality and life of the equipment.

LS Solution:

• Core Technology Application:We initially explored and decided to utilize five-axis linkageCNC machining technology.It is the ideal solution for processing such complex geometry (such as multi-angle positioning holes and internal grooves). It can realize multi-faceted machining at the same time with high accuracy, ensuring the spatial relationship between all of the features is absolutely accurate.
• Successful collaborative response:Once the project started, we used the web-based platform for instant quotation and rapid sharing of design data. The engineering group worked together with the customer to carry out design for manufacturability analysis (DFM) and provide optimization suggestions, significantly streamlining the project response and pace of progress.
• Strict quality control:Precision comes first. We took an extremely strict quality inspection process and used precision coordinate measuring machines (CMM) and other equipment to ensure that the processing error of each critical dimension is strictly controlled within ±0.01mm (the same as about 1/8 of the thickness of a hair), which provides a solid ground for perfect assembly.

Project results:

1. Speed up delivery:With efficient processes and outstanding quality, we were able to reduce the overall delivery cycle of the components by 25%, thereby allowing customers to speed up the production pace.
2. Performance leap:The perfect attainment of processing precision immediately facilitated the bracket to be constructed in its proper form within the customer's overall machine assembly simultaneously, greatly increasing efficiency and entirely eliminating the inconvenience of constant repairs. Above all, the precise matching minimized wear and stress during operation significantly, essentially extending the life of the equipment.
3. Increase cooperation:Owing to the excellent quality, delivery and technical response performance of this project, the customer has strengthened a strong confidence in our capability and has placed subsequent multiple batches of customized orders. The two sides have attained a successful establishment of a solid long-term strategic alliance.

This case precisely demonstrateshow LS utilizes advanced manufacturing technology (five-axis CNC), digital collaborative system (online quotation and design communication) and strict quality control system to help customers overcome the manufacturing bottleneck of high-precision complex structural parts, not only achieving short-term project goals (quick delivery, flawless assembly, and long life), but also securing long-term trust and cooperation of customers. We are very proud to be a reliable technical partner of customers.

Why Choose LS As Your Precision Parts Manufacturing Partner?

We know that in today's competitive manufacturing environment, a reliable partner makes all the difference to the success of your project. Here are the leading reasons why many industry-leading customers choose LS:

1. One-stop online portal: maximum efficiency, significantly reducing procurement time costs

• Pain point solution:The conventional process of parts procurement typically involves back-and-forth questions, lengthy email exchanges, and ambiguous drawing revisions, which takes a lot of time and effort.
• LS solution:We are an extremely integrated one-stop web-based customization, quotation and handling management system. All you need to do is upload3D models/drawings, and the system can perform intelligent analysis and provide transparent and explicit quotations in a matter of minutes. The system provides real-time design feedback (DFM), visibility of order status, file management and online communication, so that the cumbersome procurement process becomes digital, transparent and effective. That is, you can free valuable engineering and procurement manpower from time-consuming coordination, focus on core business innovation, and reduce the intangible "time cost" significantly.
  

2. Top equipment + best technical team: the underlying guarantee for high-quality delivery of complex parts

• Pain point solution:Complex structure parts with high precision requirements (such as multi-axis linkage processing parts, thin-walled parts, and difficult-to-process material parts) require cutting-edge processing capacity and deep process experience, or otherwise it is very simple to have lower precision, delayed delivery, or even risk of scrap.
• LS solution:We continue to invest in and commission the world-class multi-axis linkageCNC machining centers(e.g., five-axis), high-precisionCNC turningand milling compound centers, Swiss-type Swiss-type lathes and other state-of-the-art machines. Most importantly, the operations of these equipment are supported by a team of veteran and experienced engineers and technicians. Not only are they skilled in programming and operation, but also experienced in major technologies including material properties, cutting process optimization, fixture design, and control of thermal deformation. They can successfully convert complex design blueprints into high-quality physical products with consistent quality from the first piece to batch. With LS, it is selecting technical power to transform "impossible processing" into "precise realization".

3. Elastic and flexible production capacity: exactly meet demand and provide stable and assured delivery

• Problem Statement solution:Project demand is unstable and the market is volatile. Only mass-volume orders can be handled by the suppliers, so trial mass-volume production is a costly and time-consuming task, or the tight production capacity keeps delaying the delivery time and again, irritating your production plan.
• LS solution:We have developed a very elastic production system. Whether it is small-volume R&D proofing, middle-volume transitional manufacturing, or large-volume stable supply, we are capable of responding efficiently. With scientific scheduling system, modular manufacturing units and lean management, we ensure the optimal utilization of resources and capacities. This flexibility ensures that we are able to rightly map your requirements at different stages and batches, and deliver agreed time of delivery with very high reliability, becoming stable and reliable link in your supply chain.

4. Transparent and rational pricing model: Help customers save costs sustainably

• Pain point solution:Unclear quotations, hidden charges, and unwarranted price increases are common pain points in the industry, which lead to unmanageable overall procurement costs and hassle in adequate budgetary control.
• LS solution:We firmly believe that the core of collaboration lies in trust, and trust begins with transparency. We have a well-defined and logically accurate pricing format. The online quotation system presents clearly the primary cost factors such as material cost, process time (based on process evaluation), surface treatment, and management cost, which add no additional cost unbundled. We continue to go down the costs through process flow streamlining, improved material utilization, bulk procurement and lean manufacturing, and reflect this share of the benefits on the fair quotation to the customers.Choosing LS, not only are you able to trace where every penny is spent transparently but are also able to introduce long-term cost procurement optimization and general supply chain efficiency enhancement with our continuous lean improvement.

Choosing LS, you not only choose a parts processor, but also a strategic partner who is committed to offering value for you in every way through technological innovation (leading equipment + team), process innovation (one-stop platform), and model innovation (flexible production + transparent pricing).Our goal is to be your most capable and efficient "external manufacturing department" to help you minimize product time to market, improve product quality, optimize supply chain cost reductions, respond to shifting markets, and ultimately achieve a competitive advantage.

We look forward to being your partner on your next project with professional enthusiasm and real service!

Summary

Through the application of four basic methods, namely high-precision programming simulation, advanced fixture rigidity optimization, precision tool path planning, and strict process monitoring compensation,special CNC machiningis able to significantly improve the accuracy of complex brackets to the micron level. Not only does this ensure the parts fit the model perfectly and are able to withstand harsh working conditions, but also improves the overall performance and dependability of the product. Choosing a businessCNC partneris a great investment in precision, efficiency and quality.

No need to hesitate, take action now:

• Upload design drawings:Upload bracket drawings (STEP/IGES and other formats) in a few simple steps to start the high-precision manufacturing journey.
• Enjoy free consultation and samples:Get professional DFM advice and enjoy free sample production support to verify accuracy in advance.
• Get fast and accurate quotes:Get transparent quotes and delivery dates immediately to accelerate project decision-making and implementation.

Professionalonline CNC machiningis your best choice to improve bracket accuracy and efficiently advance projects!

📞Tel: +86 185 6675 9667
📧Email: info@longshengmfg.com
🌐Website:https://lsrpf.com/

Disclaimer

The contents of this page are for informational purposes only.LS seriesThere are no representations or warranties, express or implied, as to the accuracy, completeness or validity of the information. It should not be inferred that a third-party supplier or manufacturer will provide performance parameters, geometric tolerances, specific design characteristics, material quality and type or workmanship through the LS network. It's the buyer's responsibilityRequire parts quotationIdentify specific requirements for these sections.Please contact us for more information.

LS Team

LS is an industry-leading companyFocus on custom manufacturing solutions. We have over 20 years of experience with over 5,000 customers, and we focus on high precisionCNC machining,Sheet metal manufacturing,3D printing,Injection molding,Metal stamping,and other one-stop manufacturing services.
Our factory is equipped with over 100 state-of-the-art 5-axis machining centers, ISO 9001:2015 certified. We provide fast, efficient and high-quality manufacturing solutions to customers in more than 150 countries around the world. Whether it is small volume production or large-scale customization, we can meet your needs with the fastest delivery within 24 hours. chooseLS technologyThis means selection efficiency, quality and professionalism.
To learn more, visit our website:www.lsrpf.com