Projects

High-Tolerance Machining of Complex Components

At FRS Machining, we recently completed an impressive project that highlights our expertise in precision manufacturing and problem-solving. This job required producing high-precision components with extremely tight tolerances, including ±0.0001" in some areas, while maintaining consistency across multiple setups.

The parts featured complex elements such as deep internal threads, smooth radii, and a critical port feature, all machined from solid material. With eight detailed operations needed to bring these components to life, our team ensured flawless execution at every step. Despite the demanding nature of the work, we were able to deliver these parts to the customer in a timely manner and help them finish their critical build—an achievement that underscores our commitment to excellence.

This project showcases our ability to manage intricate manufacturing challenges while meeting the highest standards of quality.

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Adding tight precision features to imprecise cast parts at scale

These castings come in with draft, irregular features and a lot of variation with flatness and profile. Despite that there are critical features that must meet exact specifications in the finished state.

FRS worked closely with the customers engineering team to develop processes that ensure these high volume castings work right every time in their precision application. This enabled the customer to leverage the low cost casting process where dimensions are less critical and apply additional precision only where needed.

Had these been machined completely from billet the cost would have been nearly 10X what this solution ended up being allowing our customer to scale to full rate production faster and at less cost to the end user.

Precision Engineering for Safety-Critical Applications: Case-Hardened Propeller Shaft

FRS Machining recently completed a complex project producing a case-hardened propeller shaft for a customer’s safety-critical application. This challenging part demanded exacting tolerances and advanced machining strategies to ensure reliability in its final use.

The shaft’s long cylinder and bore had to be concentric within 0.001”, with diameters accurate to within tenths—a true test of precision machining. Inside the bore, deep undercuts added another layer of complexity, requiring the design and use of custom tooling. Careful planning was essential to create a turning strategy that preserved the integrity of other critical features throughout the process.

Adding to the challenge, the component featured custom threads that needed to meet stringent fit classifications while achieving an exceptional surface finish. With every detail expertly machined, the part underwent a case-hardening process to enhance durability and ensure it met the high standards required for its safety-critical role.