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  • Writer's pictureDiversified Designs

Project of the Week of 06/05/07

Project of the week is a Dual Balance Wheel Housing made of Black ABS. This part was eventually injection molded once tested and proven. This part is roughly 5 x 2-13/16" x 1-13/32 with a typical 0.080 wall. We can't explain what this product is or what it was used for other than it belonged to some type of audio system. Biggest challenge to this part was the middle arch; it was thin and was constantly breaking and cracking. We machined 40pcs of these in 3 variations which we cannot disclose.

End Mills, Ball Mills, Corner Round Mills and Chamfer Mills were solid carbide from Premium Carbide Tool with standard High-Speed Drills. We used Mic6 aluminum plate for fixturing in order to hold down and prevent the delicate arch wall from cracking. Overall part tolerance was +/- 0.015 the machine finish with chamfer edges and machining marks for this part was expectable for destructive testing. Now the issue with the arch was easily saved with the use of the fixture plate, embedding the arch in the plate kept the arch from flexing and cracking when being cut. This project to start the week of 06/05/07, would not have been possible without the smart fixturing layout, it did take several scrapped parts before we got the arch to survive the cut at a high rate of speed. We would like to thank our customer for allowing us to share this one and only project with people who value the manufacturing talent that is out there... If you have similar projects like this and would like to receive a quote from us, please reach out to us for further information.

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