cnc, aerospace, precision, rapid prototype
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Commercial Aviation Bracket Redesign

Tier 1 Aerospace Supplier, USA, Kansas

A Tier 1 aerospace supplier needed to improve a legacy bracket design requiring 3 welded components. PiPrecision engineered a single-piece machined solution using 7075-T6 aluminum, eliminating welds, reducing weight by 40%, achieving 60% cost reduction and 50% lead time improvement.

60%
Cost Reduction
-50%
Lead Time
40%
Weight Savings
Zero
Defects

The Challenge

The legacy design used 3 separate components requiring welding, causing weld quality variations, dimensional instability from welding stress, high assembly labor costs, and long lead times for welded assembly.

Our Solution

Single-piece machined design using 7075-T6 aluminum eliminating welds, 5-axis CNC machining of complex geometry, hard anodized black finish, full AS9102 First Article Inspection, and material traceability documentation.

The Results

60% cost reduction, 50% lead time improvement, 40% weight reduction, zero defects in 5,000+ unit production run, established ongoing production partnership for aircraft programs.

Project Gallery

cnc, aerospace, precision, rapid prototype

Project Info

Industry
Aerospace
Service
CNC Milling Service
Client
Tier 1 Aerospace Supplier
Location
USA, Kansas
Completed
July 2024

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