High-precision CNC machining combining multi-operational milling, turning and mill-turn platforms to deliver tight-tolerance metal and polymer components from prototype to production. Single-setup mill-turn strategies and in-process probing reduce setups and stack-up error, enabling complex geometries, repeatable tolerances and scalable runs for aerospace, medical and industrial customers.

CNC Machining is subtractive manufacturing performed on computer-numerically controlled machine tools. Toolpaths generated from CAM drive multi-axis milling, turning, and mill-turn equipment to remove material accurately and repeatably. The approach enables tight tolerances, stable process capability, and scalable automation for prototypes through production across metals and engineering plastics.

CNC Machining

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

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

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

Wire EDM Straight & Taper Cutting profiles conductive workpieces with a continuously fed brass or coated wire, achieving kerf widths only marginally larger than the wire diameter. Servo-controlled upper and lower nozzles permit taper angles up to ±30 ° while maintaining dimensional accuracy to ±0.002 mm across the cut thickness.

Wire EDM Straight & Taper Cutting

Sinker (RAM) Electrical-Discharge Machining plunges a custom-shaped graphite or copper electrode into a dielectric-oil gap, eroding hardened tool steels, carbide and super-alloys by controlled spark discharge. The process delivers blind cavities, sharp internal corners and deep ribs that are impossible to mill, with ±0.0002 in accuracy and Ra ≤ 8 µin surfaces after multi-skim finishing passes.

Sinker EDM

Precision CNC Machining (Milling, Turning & Mill‑Turn)

In‑house tooling and die-making capability for prototype and production tooling: progressive dies, injection‑mold inserts, fixtures and precision gages. Combines 5‑axis machining, wire/sinker EDM, jig grinding and controlled heat‑treat to deliver hardened, production‑ready tooling validated with CMM inspection and life‑cycle projections.

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)

CNC machining, EDM and polishing of hardened tool-steel or carbide extrusion dies and mandrels, delivered ready for production with flow-balance verification and bench proofs.

Die Manufacturing (Tool & Die)

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 Design & Fabrication (Die, Mold & Fixture)

Integrated engineering, prototyping and DFM services that translate concepts into production‑ready designs. Offers CAD/CAE, tolerance stack analysis, FEA validation, rapid prototype builds and CAM/post‑processing to shorten validation cycles and reduce COGS through manufacturability optimization and early tooling strategy.

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

Rapid, multidisciplinary build of functional prototypes that bridge industrial design and engineering validation. Combines additive manufacturing, CNC machining, soft tooling, electronics integration, and functional testing in tight sprint cycles to prove form-fit-function and gather user feedback before production tooling.

Prototype Development (Concept-to-Function)

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

Provides end-to-end mechanical design of components and assemblies with integrated finite-element analysis. Engineers create parametric 3-D models, run linear/non-linear static, thermal, vibration, and fatigue simulations, and iterate designs for manufacturability, cost, and compliance. Deliverables include native CAD, detailed drawings, and FEA summary reports.

Mechanical Engineering Design & FEA

Engineering, Prototyping & DFM Services

Comprehensive inspection and quality‑assurance services with calibrated metrology, process control and traceable documentation. Capabilities include bridge/gantry and portable CMMs, model‑based inspection, SPC, first‑article inspection (AS9102/PPAP) and gauge calibration to support regulated aerospace, medical and defense supply chains.

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

Digital inspection workflow extracting PMI from native CAD to generate QIF-based CMM routines and model-based inspection reports.

Model-Based Definition (MBD) Data Capture

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

Inspection & Quality Assurance (CMM, AS9100/FAI)

In‑house secondary operations and value‑added services that complete parts and assemblies prior to shipment. Services include deburring, tumbling, surface treatments, plating/anodizing, light assembly, marking, kitting and custom packaging—reducing subcontracting, lead time and supply‑chain overhead for customers.

Secondary operations & value-added services encompass in-line or post-process tasks—deburring, tapping, assembly, labeling, special cleaning or final customization—that manufacturers perform in-house but typically do not sell as stand-alone services. This catch-all pillar groups low-visibility steps so buyers understand a supplier’s complete in-house capabilities without cluttering the primary taxonomy.

Secondary Operations & Value-Added Services

Deburring is a critical post-processing operation that removes sharp edges and burrs from metal parts resulting from machining operations. It is essential for ensuring part functionality, safety during handling, and preparing surfaces for further finishing processes. Deburring can be performed using manual techniques, mechanical methods, or through thermal energy, and is applicable across a wide range of industries where smoothness of the part surface is required.

Deburring

Surface treatment & finishing encompasses chemical, mechanical and thermal operations—tumbling, vibratory deburr, abrasive blasting, electropolishing, anodizing, chromate conversion, hard-chrome or nickel plating, powder coating, wet painting and ceramic or PVD/CVD overlays—that modify a part’s surface for appearance, corrosion resistance, wear protection or adhesion. Processes routinely achieve ≤ 8 µin Ra finishes, controlled coating thickness from 0.0001 in to 0.010 in and salt-spray performance exceeding 1 000 h to ASTM B117.

Surface Treatment & Finishing

Plating involves coating a metal part with a thin layer of another metal—such as gold, silver, nickel, or zinc—through electrochemical processes. This enhances appearance, corrosion resistance, and electrical conductivity, used widely in electronics, automotive, and jewelry.

Plating

Value-Added Services (VAS) encompass a suite of post-manufacturing activities that enhance the finished product and streamline supply-chain fulfillment. Typical services include light mechanical or electromechanical assembly, kitting, custom packaging and labeling, product personalization, logistics coordination, and final inspection/testing for regulatory compliance. VAS operations are highly configurable to meet unique customer requirements, reduce total landed cost, and accelerate time-to-market.

Value Added Services

Assembly & Integration Services encompasses mechanical fastening, ultrasonic welding, heat staking, electronics and hardware integration, sub-assembly kitting, and packaging services to deliver complete assemblies or kits ready for immediate installation or shipment.

Assembly & Integration Services

Secondary Operations & Value‑Added Services

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

Excello Tool Engineering & Manufacturing Company is a precision machining job shop founded in 1960, providing CNC milling, CNC turning, rapid prototyping, and inspection services from a 50,000+ sq ft facility in Milford, CT. AS9100-certified, Excello supports aerospace, automotive, medical, government and industrial programs with close-tolerance components and assemblies, coordinate measuring inspection, material and calibration certifications, and flow-down compliance for DFAR/ITAR where required.

Primary headquarters with over 50,000 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

AS9100-certified precision CNC milling, turning, prototyping, and inspection from a 50,000+ sq ft Milford, CT facility.

Excello Tool

Precision CNC Milling And Turning

Precision CNC Machining (Milling, Turning & Mill‑Turn)

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Business Entity

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