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CASE STUDIES

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PROJECT OVERVIEW

Precision Extrusion for Military Communication Devices

Project required multiple extruded parts to serve as structural components for a communication device mounted on military vehicles. These components needed to ensure uninterrupted satellite communications in extreme conditions, demanding:

  • Tight extrusion tolerances

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  • A reliable seal

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  • Precise alignment and fitment

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  • Consistent performance under demanding conditions

The Challenge

Achieving the necessary performance specifications posed several challenges:

  • Maintaining uniform symmetry at extrusion while adhering to strict tolerances.

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  • Preventing air leaks that led to insufficient compression during assembly.

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  • Addressing variations in fastener diameters, as initial heli-coil solutions did not account for sealing challenges.

The Solution

To overcome these challenges, our team implemented key process improvements:

  • Dimensional Consistency: Adjusted the die to correct dimensional issues and collaborated with the SMS inspection team to ensure proper stress relief, eliminating asymmetry in extrusion.

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  • Structural Fitment: Modified the heli-coil and fastener system to restore precise alignment, ensuring robust structural integrity and an airtight seal.

The Result

Our refinements enabled the communication device to meet stringent military requirements, ensuring:

Reliable performance under extreme stress

Consistent structural alignment for seamless assembly

Optimal sealing to prevent air leaks

Consistent repeatability for large-scale production

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PROJECT OVERVIEW

Precision Handguard Extrusions for High-Performance Firearms

A leading high-performance firearms manufacturer approached us to extrude their proprietary handguards, requiring:

  • Tight dimensional tolerances of ±.005 inches

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  • Superior symmetry, straightness, and twist control exceeding industry standards

 

  • Advanced surface finish callouts for a flawless aesthetic

 

  • Extreme rigidity and stability using 6000-series aluminum, ensuring corrosion resistance and long-term durability

The Challenge

Achieving these precise specifications presented several challenges:

Material Challenges

  • 6000-series aluminum, while ideal for anodization and corrosion resistance, introduced surface finish issues.

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  • During quenching, water beads failed to fully dissolve, causing heat spots that affected the surface finish.

Tight Tolerance Demands

  • The required precision for straightness, symmetry, and dimensional tolerances exceeded typical industry standards.

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  • Material stretching difficulties led to asymmetry along the extrusion’s runout.

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  • Twist issues emerged, impacting fitment and machinability.

The Solution

To overcome these obstacles, we implemented a series of engineering and quality control innovations:

1. Enhanced Surface Finish & Quality Assurance

Adjusted the quenching process to eliminate heat spots before anodizing, ensuring a uniform finish.

2. Compliance & Documentation

Developed comprehensive in-process documentation to ensure compliance with all regulatory specifications and customer requirements.

3. Precision Tolerance & Structural Integrity

  • Designed custom fixtures to maintain tight tolerances and prevent profile distortion during stress relief.

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  • Established a dedicated quality inspection team, utilizing high-accuracy optical CMM machines for pre- and post-inspections.

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  • Made precise extrusion tooling adjustments based on real-time inspection data to correct asymmetry and twist.

The Result

Our expertise and process refinements led to:

Flawless, anodization-ready surface finishes

Unmatched precision in straightness, symmetry, and fitment

Consistent repeatability for large-scale production

Reliable, high-performance handguards meeting the strictest industry standards

This project reinforced our ability to engineer high-precision extrusions for the firearms industry, delivering both functionality and aesthetics without compromise.

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