Equipped with advanced 3-axis and 5-axis vertical machining centers, our CNC milling capabilities enable precision machining of complex parts with tight tolerances. Our machinery, including the Haas VF-5/40TR, Fadal VMC 4020, and Fadal VMC 6030, supports a wide range of materials and part sizes, making us suitable for applications demanding high precision.

CNC-Machined Components for Dry Solids Handling Equipment

Face Milling is a machining process where the cutting tools are perpendicular to the workpiece, removing material from its surface to create a flat face. This technique is ideal for achieving high-quality finishes and flat surfaces on the workpiece. Face Milling is widely used in various applications, including the production of flat surfaces on castings and forgings, as well as for preparing surfaces for further processes.

Face Milling

Plain Milling, also known as slab milling, is a process that involves using a horizontal or vertical milling machine to produce flat surfaces. This milling operation uses a cutting tool with multiple cutting edges to remove material from the surface of a workpiece in a horizontal plane, creating a flat or squared surface.

Plain Milling

Angular Milling is a process where the milling cutter is positioned at an angle relative to the surface of the workpiece. This technique is used to create angular features such as chamfers, serrations, and grooves. It requires specialized angular cutters and is known for its precision in creating intricate angular geometries.

Angular Milling

Form Milling involves the use of milling cutters of a specific form to create curved or irregular surfaces on the workpiece. This process is utilized for milling complex shapes and profiles such as contours, grooves, and channels. Form milling requires cutters shaped to the contour to be cut, making it highly versatile for custom shapes.

Form Milling

Reaming is a finishing process used in CNC milling to slightly enlarge holes and improve their accuracy and surface finish. This process is performed using a reamer and is essential for precise hole specifications, ensuring tight tolerances and a smooth interior surface of the hole, often required in high-precision engineering applications.

Reaming

Tapping is a process in CNC milling used to create internal threads within a hole, allowing for the insertion of a threaded bolt or screw. This process requires precision to ensure thread integrity and alignment. Tapping is widely used across various industries, particularly in assembly and mechanical components where threaded fastening is essential.

Tapping

Counterboring is a machining process that enlarges a hole to a specific diameter and depth, often to accommodate a bolt head or nut. This process ensures that fasteners sit flush with or below the surface of the material, providing a neat finish and structural integrity. Counterboring is commonly performed after drilling and is vital in mechanical assemblies where precision and aesthetics are crucial.

Counterboring

Countersinking involves creating a conical hole that matches the angle of a flat-head screw or bolt. This process allows the head of a fastener to sit flush with or below the surface of the material. Countersinking is essential in applications where a smooth surface is needed and is commonly used in carpentry, metalworking, and manufacturing industries.

Countersinking

Slot Milling is a process where a milling cutter is used to create slots or grooves in a workpiece. This operation is essential for creating keyways, slots for components, and other features that require precise grooves. Slot milling can be performed on various materials and is critical in manufacturing industries for component assembly and mechanical functions.

Slot Milling

Surface Milling, also known as face milling, involves removing material from the surface of a workpiece to produce a smooth, flat surface. This process is widely used for finishing operations and in creating large flat surfaces with high precision. Surface milling is vital in automotive, aerospace, and mold-making industries.

Surface Milling

Gear Milling is a specialized process used to create gear teeth profiles on a workpiece. Utilizing specialized cutters and precise calculations, this process is essential for manufacturing various types of gears used in automotive, machinery, and equipment industries. Gear Milling requires high precision to ensure the proper functioning of the gear mechanism.

Gear Milling

Drilling is a versatile machining process used across various manufacturing methods, including CNC milling and turning. It involves creating precise holes in a material using a drill bit. This operation is vital for achieving accurate hole placement with varying diameters and depths. Drilling is known for its ability to produce clean, straight cylindrical holes and is utilized across diverse materials like metals, plastics, and wood.

Drilling

Boring is a precision machining process focused on enlarging pre-existing holes in a material. This operation is essential in both CNC milling and turning, where it's used to achieve greater accuracy and smooth internal surface finishes. Boring allows for the creation of holes with tight tolerances and is often employed in applications requiring precise hole sizes, such as in engine cylinders and hydraulic systems.

Boring

Simultaneous 5-Axis Machining enables continuous, synchronized movement of all five machine axes, drastically reducing setups and facilitating the creation of highly intricate geometries with superior surface finishes.

Simultaneous 5-Axis Machining

CNC Milling is a precise and versatile computer-controlled manufacturing process that involves the removal of material using rotary cutting tools to create shapes, holes, and details in a workpiece. This process is capable of producing complex parts with high accuracy and excellent surface finish. CNC milling machines operate on multiple axes (3-axis, 4-axis, or 5-axis) allowing for intricate and precise cuts, suitable for a wide range of materials including metals, plastics, and composites.

CNC Milling

CNC routing is a manufacturing process involving a computer-controlled router tool to cut, shape, and design various hard materials, such as wood, composites, aluminum, steel, plastics, glass, and foams. It's widely used for tasks like cutting intricate designs and producing high-precision parts. CNC routers are similar to CNC milling machines, offering high precision and the ability to produce complex shapes with smooth finishes. They are extensively used in woodworking, sign making, mold making, aerospace, automotive, and in the production of countless other industrial and consumer products.

CNC Routing

Machining encompasses a variety of manufacturing processes aimed at shaping and removing material from a workpiece. This includes both computer-controlled processes, such as CNC milling, turning, and routing, as well as non-traditional methods like Electrochemical, Chemical, and Photochemical Machining.

CNC Machining

Commercially pure aluminum, excellent corrosion resistance and formability.

High strength, fatigue resistance, used in aerospace components.

Good corrosion resistance and weldability, used in cookware and chemical equipment.

High strength, corrosion resistance, and weldability, used in marine and automotive applications.

Versatile structural alloy with good corrosion resistance, used in construction and aerospace.

Very high strength, used in aerospace and military applications.

A lightweight, corrosion-resistant metal with high thermal and electrical conductivity, widely used in various industrial applications.

Aluminum

A low-carbon steel used in structural applications, offering good weldability, machinability, and can be heat treated to harden its surface.

A low-carbon steel that exhibits good ductility, toughness, and strength. It is often used for parts requiring cold forming, such as crimping, swaging, or bending.

Carbon steel is an alloy of iron and carbon, with carbon content up to 2.1% by weight. Additional elements are present in small quantities, including manganese, silicon, and copper. Carbon steel is classified based on carbon content: low, medium, and high carbon steel, with increasing carbon content leading to increased hardness and strength but decreased ductility. It is widely used in construction, automotive, and manufacturing industries due to its strength and versatility.

Carbon Steel

Cartridge brass, with 70% copper and 30% zinc, known for its high strength and ductility.

Free-machining brass, with excellent machinability used for high-speed machining operations.

Architectural bronze, used in extruded and architectural sections for its strength and appearance.

An alloy of copper and zinc, known for its strength, ductility, and corrosion resistance, along with a distinctive yellowish color. Used widely in decorative, musical, and mechanical applications due to its machinability and acoustic properties.

Brass

A chromium-molybdenum steel with high toughness and strength at elevated temperatures.

A nickel-chromium-molybdenum steel known for its toughness and strength.

A high carbon, chromium steel used in bearings and high-wear applications.

A low-carbon nickel-chromium-molybdenum steel, widely used for gears and shafts due to its toughness and machinability.

Steel that is alloyed with a variety of elements in total amounts between 1.0% and 50% by weight to improve its mechanical properties.

Alloy Steel

Also known as Electrolytic Tough Pitch (ETP) copper, it is highly ductile and has high electrical and thermal conductivity.

Beryllium copper, known for its high strength and hardness, making it ideal for electrical connectors and springs.

Also known as 90/10 copper-nickel, offers excellent resistance to marine corrosion and biofouling.

Copper is a highly conductive metal used extensively for electrical wiring, roofing, plumbing, and industrial machinery. It is known for its excellent electrical and thermal conductivity, malleability, and resistance to corrosion. Copper's thermal conductivity enables its use in heat exchangers and air conditioning units. Its antimicrobial properties make it ideal for medical and architectural applications.

Copper

The most common stainless steel, known for good corrosion resistance, weldability, and formability.

Similar to 304 but with added molybdenum for significantly better corrosion resistance, especially in chlorinated environments.

Stainless Steel is a group of iron-based alloys containing a minimum of approximately 11% chromium, a composition that prevents the iron from rusting and also provides heat-resistant properties. Different types of stainless steel include the elements carbon (from 0.03% to greater than 1.00%), nitrogen, aluminum, silicon, sulfur, titanium, nickel, copper, selenium, niobium, and molybdenum. Specific additions of nickel and molybdenum enhance corrosion resistance in acidic and chlorine-bearing environments, making it an ideal material for various applications across industries.

Stainless Steel

Haas VF-5/40TR

Fadal VMC 4020

Fadal VMC 6030

Supports high volume production demands, ensuring scalability and competitive cost for large-scale orders.

Meets the needs of medium volume production, offering cost efficiency for expanding product lines.

Designed for prototyping and small batch runs, allowing for rapid iteration and testing.

Optimized for low volume production, ideal for market introduction and specialized products.

3- to 5-Axis CNC Milling

Our CNC Turning process is equipped with advanced lathes capable of handling a variety of materials, ensuring precision and efficiency in producing complex parts. Specializing in both small and large-scale production, we offer a wide range of turning operations, including straight turning, taper turning, and profile turning.

Straight Turning is a precise operation in CNC turning where material is removed from the exterior of a cylindrical workpiece to achieve a straight surface. It's essential for creating uniform diameters along the length of the component.

Straight Turning

Taper Turning in CNC involves cutting a conical shape into a workpiece. This operation is used to create parts that taper, typically found in shafts or fasteners, where a uniform reduction in diameter is required over the length of the part.

Taper Turning

Profile Turning is a CNC operation where complex external geometries are produced on a workpiece. It involves changing the cutting path to create various shapes like contours, arcs, and steps, crucial for customized component manufacturing.

Profile Turning

Threading is a CNC turning operation used to produce internal or external threads on a workpiece. It involves rotating the workpiece and cutting tool in synchronization to create precise screw threads, essential for components requiring threaded connections.

Threading

Facing in CNC Turning is a machining process used to produce a flat surface at the end of the workpiece. This operation involves moving the cutting tool at right angles to the axis of the workpiece, providing a smooth and finished surface.

Facing

Hard Turning in CNC Turning refers to the process of cutting materials that are hard, typically above 45 HRC, using a single point cutting tool. It is an efficient and cost-effective alternative to grinding for achieving precision dimensions and surface finishes on hard materials.

Hard Turning

Cutoff, also known as Parting, in CNC Turning is the operation where a part is cut off from the main workpiece. This process involves a deep, straight cutting operation along the workpiece to separate the part.

Cutoff (Parting)

Knurling in CNC Turning is a process of producing a regular, cross-hatched pattern on the surface of a part. This is typically done to provide a better grip on the machined part. It involves pressing a tool with the desired pattern into the rotating workpiece.

Knurling

Superimposed Machining is an advanced CNC turning technique enabling simultaneous cutting with multiple tool posts or spindles. This parallel operation dramatically reduces cycle times and increases production efficiency for complex parts.

Superimposed Machining

Live Tooling adds powered rotating tools to CNC turning centers, allowing operations like milling, drilling, or tapping on a lathe without transferring the part to a separate machine. This improves efficiency and reduces setups for complex components.

Live Tooling

Swiss Machining is a high-precision CNC machining process designed for producing small, complex parts with tight tolerances. It is typically performed on Swiss-type lathes, which utilize a sliding headstock and a guide bushing to minimize deflection and enhance precision during various machining operations, including turning, milling, and drilling. Key features include high precision and accuracy, capability for multiple operations, and minimal tool deflection. Common applications include medical devices, aerospace components, precision instruments, and electronics parts.

Swiss Machining

Screw Machining is a high-speed, precision machining process designed for the mass production of small, intricate components such as screws, bolts, and other threaded parts. Performed on automatic screw machines, it allows for multiple operations—including turning, threading, drilling, and knurling—in quick succession. This ensures efficient and accurate production of high-volume parts. Typical applications include automotive components, medical devices, electronics hardware, and various fasteners or fittings.

Screw Machining

CNC Turning is a manufacturing process where bars of material are held in a chuck and rotated while a tool is fed to the workpiece to remove material to create the desired shape. It is predominantly used for cylindrical parts and is known for its ability to achieve tight tolerances and excellent surface finishes. CNC turning is suitable for creating components like shafts, rods, and fasteners in a wide range of materials.

CNC Turning

South Bend SB1051

Sherline 3999

Precision CNC Turning

Our metal fabrication capabilities are centered around precision and versatility, able to handle complex bending and forming operations for a wide array of metal types and thicknesses.

Shearing involves cutting metal sheets or plates by applying a high-pressure tool on a metal surface, creating a straight cut.

Shearing

Sawing is a cutting process that uses a saw blade to cut through metal, typically used for cutting larger metal sections to size.

Sawing

Laser Cutting utilizes a high-powered laser to cut materials, offering high precision and speed. It's often used for complex shapes and fine cuts, including multi-axis configurations that enable more complex geometries.

Laser Cutting

Plasma Cutting involves using a plasma torch to cut through various types of metal, effective for both thick and thin materials.

Plasma Cutting

Water Jet Cutting uses a high-pressure stream of water, sometimes combined with an abrasive, to cut a variety of materials.

Water Jet Cutting

Oxy-fuel Cutting uses fuel gases and oxygen to cut through metals. It's primarily used for cutting carbon steel in heavy sections.

Oxy-fuel Cutting

Miter Cutting is a precision cutting process used in metal fabrication to produce angled cuts on the ends of a workpiece. It's commonly employed in framing and piping for proper fitting at various angles.

Miter Cutting

Oscillation Cutting utilizes a rapidly oscillating (back-and-forth) blade or cutter to slice through materials, reducing friction and heat buildup. This process is commonly used for cutting softer or layered materials, such as foam, textiles, and composite sheets, with high precision and minimal material deformation.

Oscillation Cutting

Cutting in metal fabrication refers to the process of removing material from a workpiece to create desired shapes or features. It encompasses various methods like shearing, sawing, laser cutting, plasma cutting, water jet cutting, and oxy-fuel cutting. Each method varies in its approach and is suitable for different types of materials and precision requirements. Cutting is a fundamental step in fabrication, setting the stage for subsequent forming, joining, and finishing processes.

Cutting

Cold Working comprises metal forming processes carried out below the metal’s recrystallization temperature. It increases strength and hardness through plastic deformation methods like cold rolling, cold forging, and cold drawing.

Cold Working

Stretch Forming involves stretching metal beyond its yield point and bending it over a die to achieve a desired shape, useful for large, contoured parts like automotive components and aerospace structures.

Stretch Forming

Die Forming uses a specialized tool (a die) to cut, shape, or form metal sheet or stock into specific shapes and patterns. It's well-suited for producing complex and precise components efficiently.

Die Forming

Press Brake Forming uses a press brake machine to bend and form sheets of metal with high precision, making it essential for detailed metalworking applications.

Press Brake Forming

Deep Drawing is a forming process where a metal blank is radially drawn into a die to produce parts with a high depth-to-diameter ratio, often used for seamless, high-strength components.

Deep Drawing

Forging uses localized compressive forces to deform metal into high-strength parts, commonly for engine components, hardware tools, and various machinery.

Forging

Bending deforms metal into a particular angle or shape, typically used for pipes, tubes, and structural elements.

Bending

Rolling passes metal stock through one or more pairs of rolls to reduce thickness, ensure uniformity, and achieve desired mechanical properties.

Rolling

Spinning shapes metal by rotating it and forming it around a tool, commonly used for conical or cylindrical parts.

Spinning

Forming is a manufacturing process involving the shaping of metal using localized compressive forces. It includes various methods where metal is formed into the desired shape without adding or removing material. Techniques in this process encompass bending, rolling, spinning, and more, each suitable for creating specific shapes and features in metal components.

Forming

Punching creates holes or indents in metal sheets or structures by driving a punch through the material, widely used in manufacturing.

Punching

Stamping presses metal into a die to form specific shapes and features, enabling high-volume production of uniform parts.

Stamping

Nibbling cuts a contour by moving a punch in small increments, allowing for the creation of complex shapes in sheet metal.

Nibbling

Progressive Stamping utilizes multiple stations in a single strip of metal, forming complex parts in a continuous, efficient process.

Progressive Stamping

Deep Drawn Stamping forms hollow or cylindrical parts by drawing metal into a die deeper than it is wide, yielding seamless, high-strength components.

Deep Drawn Stamping

Fourslide Stamping uses four tool slides from different angles to form intricate shapes, enabling complex parts without the need for multiple dies.

Fourslide Stamping

Punching and stamping involve shaping metal by pressing it into a die. Punching creates holes or indents, while stamping forms the metal into specific shapes.

Punching and Stamping

Cold Welding bonds metals via high pressure without heat, protecting electrical conductivity and original material properties.

Cold Welding

Plasma Arc Welding is akin to TIG but uses a constricted plasma arc for higher energy density, allowing for precision welding in aerospace and microelectronics.

Plasma Arc Welding

Submerged Arc Welding forms the weld beneath a granular flux. It's highly efficient for large structures like ships, tanks, and bridge components.

Submerged Arc Welding (SAW)

Pulsed MIG uses precisely controlled electrical pulses to stabilize the weld pool, ideal for thin metals and reducing heat input.

Pulsed MIG (GMAW-P) Welding

MIG Welding (Metal Inert Gas) continuously feeds a wire electrode while an inert gas shields the weld pool, known for speed and ease of use.

MIG Welding

TIG Welding (Tungsten Inert Gas) uses a non-consumable tungsten electrode and provides precise control, suitable for thin metals or critical welds.

TIG Welding

Stick Welding (SMAW) uses a flux-coated consumable electrode. It's robust, portable, and commonly used for outdoor or on-site welding.

Stick Welding

Flux-Cored Welding is similar to MIG but uses a tubular electrode filled with flux; often preferred for heavy fabrication and high deposition rates.

Flux-Cored Welding

Spot Welding fuses overlapping metal surfaces via resistive heat from an electric current, frequently used in automotive assembly.

Spot Welding

Brazing joins metals by melting a filler alloy with a lower melting point than the base metals, effective for leakproof or complex assemblies.

Brazing

Soldering uses a lower-melting-point filler to join metals, commonly used in electronics, plumbing, and jewelry applications.

Soldering

Riveting uses a metal pin with a head, deforming or 'bucking' the opposite end to fasten materials together, common in aerospace and structural assemblies.

Riveting

Gas Welding uses a flame produced by oxygen and acetylene to melt and fuse metals, commonly used in repair work and for thinner sections.

Gas Welding (Oxy-Acetylene Welding)

Laser Beam Welding uses a focused laser to fuse materials, allowing for high-precision, high-speed welding of thin metals in automotive, aerospace, and electronics.

Laser Beam Welding (LBW)

Electron Beam Welding uses a beam of high-velocity electrons in a vacuum for deep penetration and minimal distortion, critical in aerospace and nuclear sectors.

Electron Beam Welding (EBW)

Friction Welding generates heat via mechanical friction between parts, commonly joining dissimilar metals in automotive and aerospace applications.

Friction Welding

Ultrasonic Welding applies high-frequency acoustic vibrations under pressure to form solid-state bonds, often used in electronics and plastics.

Ultrasonic Welding

Explosion Welding uses controlled explosives to bond metals, creating a high-velocity impact that can fuse even dissimilar alloys.

Explosion Welding

Induction Welding uses electromagnetic fields to heat materials internally, commonly for pipes, tubes, and continuous manufacturing lines.

Induction Welding

Arc Welding uses an electrical arc to fuse metals, typically employing a consumable or non-consumable electrode. This technique is widely used for structural and industrial applications, offering strong, reliable welds on a variety of metals.

Arc Welding

Welding and Joining processes fuse metal parts together using heat, pressure, or both. Common methods include MIG and TIG welding, soldering, and brazing.

Welding and Joining

Metal Fabrication is the process of building metal structures by cutting, bending, and assembling processes. It involves the creation of machines, parts, and structures from various raw metals. Metal fabrication is a critical process in industries such as construction, automotive, aerospace, and consumer products, offering the versatility to create a wide range of components and end products.

Bushkill Tool

Precision CNC Machining & Custom Fabrication

3- to 5-Axis CNC Milling

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Aluminum

Carbon Steel

Brass

Alloy Steel

Copper

Stainless Steel

High-Precision CNC Machining for Industrial Equipment Components 4.8

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