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Four-Axis Milling of Aluminum Amplifier Housing for Communications Industry

At Solutions Manufacturing we’ve had a long history of imparting a positive impact on our customers’ project cost, manufacturability, and critical end-use performance. This complex electronic chassis designed for use in the communications industry was completed in three machining operations.

We started with sawed ASTM certified 6061-T651 aluminum blanks supplied by one of our approved material vendors. The first operation prepared the aluminum blanks to be mounted on a 4th axis turntable, using an in-house designed and built vacuum chuck. Utilization of the custom vacuum fixture made clamps unnecessary, thereby allowing all external part features to be machined in a single operation. In the 3rd and final machining operation all features of the complex internal pocket were completed. Next the external surfaces were treated to develop a 240 grit directional grain.

Our cost saving ingenuity on the project didn’t stop there. The demanding communications application called for all internal surfaces of the chassis to be treated with a chromate conversion process while all external surface received a black anodize treatment. In conjunction with an approved finishing vendor, we developed a cost saving masking process that employed reusable covers and gaskets along with polyester masking tape by which we avoided a costly paint masking operation. Next the chassis’ had the customer specified marking scheme applied using a Cool Grey, thermo set screen ink (silk screen).

Each of the processes both internal and external were monitored through a comprehensive quality plan to assure 100 percent customer satisfaction. After the part's final inspection, the chassis’ were boxed using custom packaging to insure they arrived safely to our customers electrical assembly lab. To learn more about this project, or how our “complete solution” can benefit your operation, contact us today.

Highlights of Custom Machined Amplifier Housing

Product Name
Capabilities Applied/Processes
  • 4 Axis CNC Milling

  • Directional Grain Surface Application
  • Finishing Operations
  • Silk Screen Operation
  • Custom Packaging
Overall Part Dimensions
Length: 5.980"
Width: 12.250"
Tightest Tolerances
Material Used
6061-T651 Aluminum Plate per B209
Material Finish
Directional Grain Surface Application
Black Anodized with Masking
Additional Facts
Applied Artwork and Lettering – Silk Screeing
In process testing/inspection performed
Dimensional and Visual Inspection
Industry for Use
250 Units
Delivery/Turnaround Time
7 weeks
Delivery Location
Schaumburg, IL
Standards Met
Customer Specifications, 2D CAD Drawing
RoHS Compliant
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