High-mix precision milling on 3-, 4- and 5-axis platforms with palletized cells for rapid changeover and unattended production. One-and-done strategies, in-process probing, and CMM-verified buyoffs drive tight, repeatable results from prototypes through production. Representative cell mix includes Toyoda/Kiwa HMCs and Haas UMC-500/UMC-500SS for complex, multi-face geometries and aggressive takt times.

CNC tool holders with precision end mills for high-accuracy machining operations

CNC milling process with coolant application for improved surface finish and tool life

Precision CNC machined components with complex geometries and tight tolerances

CNC Milling removes material with rotating cutters under precise multi-axis computer control, producing complex prismatic or sculpted parts with positional accuracy to ±0.005 mm and surface finishes ≤ Ra 0.4 µm. Machines span 3-axis vertical mills, 4-axis horizontals with pallet changers, and full 5-axis trunnion or gantry platforms, supporting everything from rapid prototypes to lights-out production in metals, plastics, and composites.

CNC Milling

By evaluation; may recommend alternate process if more cost-effective.

Palletized flow; lights-out for repeat geometries.

Rapid iteration; fixture concepts included when useful.

High-mix cells with quick changeover and SPC.

Employs pallet changers and queued job scheduling for lights-out milling of high-volume cast-part trimming operations.

Automated Pallet Machining

On-machine touch or scanning probes measure features during the machining cycle to establish/reconfirm datums, verify critical dimensions, detect broken tools, and apply automatic compensation (work offsets/tool wear). Enables adaptive machining for cast/forged stock variation and supports unattended runs.

In-Process Probing

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

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

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

Material-removal process performed on horizontal-spindle machining centres (HMCs). Workpieces are fixtured on pallets or tombstones; the horizontal orientation promotes gravity-assisted chip evacuation and permits simultaneous 4th-axis indexing for multi-face machining in one setup.

Horizontal CNC Milling

Precision 3- to 5-Axis CNC Milling

Close-tolerance turning with live-tooling, Y-axis and sub-spindle for one-and-done completion. Bar-fed production to ~3.125 in OD with jaw/collet chucking for larger billets. Back-working synchronizes part transfer to finish secondary features in-cycle, delivering concentricity, fine finishes, and compressed lead times on shafts, manifolds, fittings, and threaded components.

CNC Turning uses computer-controlled lathes to rotate bar, billet, or cast blanks while single-point cutting tools remove material. The process excels at producing concentric OD/ID features, tapers, threads, grooves, and complex contours with tight positional accuracy. Modern CNC lathes support live tooling, Y-axis interpolation, sub-spindle part transfer, and bar-feed automation—enabling complete, high-volume production of precision cylindrical components in metals or plastics.

CNC Turning

Bar-Fed CNC Turning automates production by feeding continuous bar stock (typically ≤ 50 mm / 2 in Ø) through the spindle. Coupled with sub-spindle or parts-catcher, it enables unattended, high-volume manufacture of precision turned components with minimal material waste and cycle time.

Bar-Fed CNC 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)

Cross Drilling produces radial or compound-angle holes that intersect a primary bore in shafts, hydraulic spools, crankshafts, and tubular parts. Live-tool turrets, B-axis heads, or mill-turn sub-spindles index the workpiece so the drilling tool can penetrate the sidewall, creating intersecting oil galleries, gas ports, or balancing holes without a secondary milling setup.

Cross Drilling

CNC Mill-Turn Machining combines multi-axis turning and milling in a single setup. Workpieces are clamped once and processed on opposed spindles with live tooling, Y-axis milling, and simultaneous interpolation up to 9 axes. This eliminates part re-clamping, improves concentricity between turned and milled features, and compresses overall cycle time for complex prismatic-plus-cylindrical components used in aerospace, medical, and high-mix/low-volume production.

CNC Mill-Turn Machining

Single-Setup Part Completion—often called “One-and-Done”—uses a 7-axis mill-turn to finish all machined features in one uninterrupted cycle, combining main-spindle work, sub-spindle back-working, live-tool milling, and probing. This eliminates secondary fixtures, shortens lead time, and locks all GD&T relationships to a single datum structure.

Single-Setup Part Completion (One-and-Done Mill-Turn)

Precision CNC Turning & Mill-Turn

Design/build of machining and inspection fixtures, nests and gauges, plus rapid prototype machining to validate form-fit-function before release. Toolroom mills, engine lathes, surface grinders, and CMM buyoffs produce rigid, datum-reliable tooling that reduces setup time, improves repeatability, and de-risks ramp to production.

Tool & Die manufacturing designs, machines and validates progressive-stamping dies, plastic-injection molds, hydroforming dies, welding fixtures and precision inspection gages. Shops integrate 5-axis machining, Wire/Sinker EDM, jig grinding and CMM verification to achieve ±0.0002 in feature positions and micro-polished shut-offs for multi-million-cycle production.

Tool & Die (Fixtures & Gages)

Designs and builds custom fixtures plus 17-4 PH stainless gauges to secure castings and verify dimensions during trimming operations.

Fixture & Gauge Manufacture

Rapid design, manufacture, and validation of prototype coiling arbors, strip-forming dies, swaging mandrels, and inspection nests tailored to spring geometries not yet in production. Combines CAD/FEA, micro-EDM, laser powder-bed fusion, and micro-milling to deliver ready-to-run tooling in ≤3 working days.

Prototype Tooling Design & Build

Design and analysis of jigs, nests and cutting tools using FEA and simulation to ensure repeatability and interchangeability.

Production Tooling & Fixture Design

Tooling, Fixtures & Prototyping

Pragmatic engineering support focused on CAD intake, DFM, and CNC programming. Translates/validates customer CAD, reviews GD&T and tolerance/cost tradeoffs, and produces collision-checked toolpaths and machine-specific posts. Delivers clean setup documentation and fixture concepts to shorten iteration and hand off cleanly to production.

End-to-end engineering and design services including CAD/CAE modeling, finite-element analysis, tolerance stack-up, DFM/DFA feedback and fixture design. Teams leverage multi-CAD platforms and PLM integration to deliver manufacturable product designs optimized for cost, performance and assembly.

Engineering & Design Services

Design-for-manufacturability and design-for-assembly consulting evaluates product designs for optimal manufacturability, assembly cost reduction and quality control. Experts deliver actionable reports on feature simplification, material selection, draft angles and assembly gauge strategies to reduce cycle times and scrap rates.

DFM / DFA Consulting

Creation of collision-free tool-paths, fixturing strategies and machine-specific post-processed NC code for 3- to 5-axis machining centres, turning, mill-turn and probing cycles, ready for shop-floor execution.

CNC Programming & Post-Processing Services

Imports and validates customer CAD data from STEP, IGES, Parasolid, ACIS, and native formats (SolidWorks, CATIA, NX, Creo). Geometry is checked for corrupt faces, missing features, and unit mismatches before downstream CAM or documentation.

CAD Model Import & Translation

Translates 3-D models and 2-D drawings between native and neutral CAD formats while preserving geometry, assemblies, metadata and PMI/GD&T annotations.

CAD File Conversion

Engineering & DFM Support

ISO-aligned quality system with in-process checks and final inspection. Capabilities include CMM layouts, optical/vision checks, surface metrology, and gauge calibration with traceable records. First-article and PPAP data packs are produced on request; inspectors support incoming, in-process, and final scopes under controlled conditions.

Inspection & Quality Control (IQC) comprises the metrology, verification, and documentation activities that ensure parts conform to drawing/CAD requirements, customer specifications, and regulatory standards. IQC spans incoming, in-process, and final inspection and leverages coordinate metrology (CMMs and portable arms), laser/structured-light scanning, optical comparators and vision systems, surface-form metrology (profilometers, roundness/contour testers), nondestructive testing (NDT), and statistical process control (SPC). Results are captured in traceable reports (e.g., AS9102 FAIR, PPAP) tied to calibrated gauges and controlled environmental conditions.

Inspection & Quality Control

Dimensional Inspection verifies that a part’s physical dimensions match design tolerances. Tools include calipers, micrometers, and CMMs, ensuring geometric accuracy of length, width, height, angles, and more.

Dimensional Inspection

3D Coordinate Measurement uses coordinate measuring machines (CMMs) or other 3D metrology tools to capture precise data points on a part’s surface, essential for verifying complex geometries and alignment.

3D Coordinate Measurement

Establishes and maintains a metrology program that calibrates dimensional gauges, torque wrenches, force and pressure transducers, and electronic inspection devices traceable to NIST or equivalent standards. Includes periodic gauge repeatability & reproducibility (Gage R&R) studies to verify measurement system capability and ensure Cp/Cpk compliance for AS9100, ISO 9001, and IATF 16949 quality systems.

Gauge Calibration & Gage R&R Management

Preparation and submission of Production Part Approval Process packages (Levels 1-5) including control plans, FMEAs, dimensional results, material certs and capability studies to satisfy IATF 16949 requirements.

PPAP Documentation & Submission

A global standard for quality management systems focusing on continuous improvement and customer satisfaction.

ISO 9001:2015

AS9100D is the 2016 revision of the aerospace Quality Management System (QMS) standard. It augments ISO 9001:2015 with aerospace-specific requirements for risk-based thinking, product safety, counterfeit-parts prevention, configuration management, and stringent supplier controls to ensure the safety and reliability of aviation, space, and defense products and services.

AS9100D

The design, manufacturing, and integration of high‐precision components, systems, and subsystems for commercial aircraft and military platforms, with emphasis on meeting stringent certifications such as AS9100, ITAR, and MIL‐STD. Priorities include advanced materials, rigorous quality assurance, and robust engineering to ensure reliability in mission‐critical applications.

Aerospace & Defense

AS9100-scoped precision machined components, housings, and fixtures with FAIR documentation on request (AS9102) and DFARS/ITAR flow-down compliance where specified.

The development, manufacturing, and supply of precision-engineered medical systems, devices, and critical components, including diagnostic equipment, surgical instruments, implantable devices, laboratory systems, and precision medical components. Emphasizes adherence to ISO 13485 and FDA QSR standards, traceability requirements, sterile processing, rigorous validation, and use of biocompatible materials such as titanium, stainless steel, and medical-grade polymers to ensure patient safety and clinical effectiveness across global healthcare settings.

Medical Devices & Healthcare Equipment

Tight-tolerance machined components, instrument bodies, and subassemblies with material certification and lot traceability suitable for regulated medical builds.

The design, manufacturing, and assembly of components and systems for passenger cars, commercial and off-highway vehicles, rail rolling stock, and emerging electric/Autonomous mobility platforms. High-volume production, IATF 16949 compliance, JIT supply chains, and continuous innovation ensure reliable powertrains, safety-critical systems, and cost-efficient delivery across a broad transportation landscape.

Automotive & Transportation

Prototype-to-production machined parts, brackets, and powertrain components with PPAP-ready inspection data and repeatable short-run delivery.

Founded in 1960, Excello Tool Engineering & Manufacturing provides close-tolerance CNC milling, turning, and 5-axis milling from a 35,000 sq ft Milford, CT facility. AS9100D and ISO 9001:2015 certified, the shop supports aerospace, medical, automotive, government, and industrial programs with CMM inspection, material and calibration certifications, and DFARS/ITAR flow-down compliance where required.

Primary headquarters with ~35,000 sq ft of manufacturing floor space housing CNC milling, multi-axis machining centers, CNC lathes, grinders, presses, and a dedicated inspection/CMM department. The facility supports precision, close-tolerance production, prototyping, and JIT deliveries with documented calibration and material certification processes to support regulated supply chains.

Excello Tool Engineering & Manufacturing Co. Headquarters

Precision CNC milling, turning, rapid prototyping, and CMM inspection from a 35,000-ft² Milford, CT facility.

Excello Tool

Precision CNC Milling, Turning & 5-Axis Machining

Precision 3- to 5-Axis CNC Milling

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