Precision 6061-T6 Stepped Circular Adapter Flange with Matte Silver Hard Anodizing for Medical Imaging Equipment

We manufactured a precision 6061-T6 stepped circular adapter flange for a medical imaging equipment application. This component serves as a critical interface between imaging system modules — requiring precise two-step end-face parallelism, accurate multi-hole positioning (both threaded and clearance holes), and tight coaxiality between inner and outer hole patterns. Machining challenges included: two-step end-face parallelism control, multi-hole position and coaxiality requirements, micro side-hole drilling with chip evacuation difficulties, and distinguishing threaded vs. clearance hole precision — all while maintaining surface integrity through hard anodizing. We applied single-setup turn-mill machining to complete both stepped end-faces in one clamping — eliminating re-fixturing errors and achieving required parallelism. Multi-hole patterns were machined referencing a single datum (the finish-bored center bore), with center-drill piloting and rigid tapping for thread accuracy (6H class) and reamed finishing for clearance holes (H7 class). Micro side-holes were drilled with high-pressure coolant-through tooling to manage chip evacuation in confined geometries. The flange was then matte silver hard anodized (Type III) with finishing allowances accounting for 10-25μm coating growth, delivering a durable, corrosion-resistant surface matching medical equipment aesthetic standards.

Project Overview

Key Technical Highlights

• Single-Setup Turn-Mill for Parallelism: Both stepped end-faces completed in one clamping on a turn-mill center — eliminating re-fixturing errors and ensuring ≤0.01mm parallelism between the two stepped surfaces. Staged roughing with 0.3-0.5mm finishing allowance, followed by light finishing passes, prevents stress-induced distortion.
• Multi-Hole Position and Coaxiality Control: All hole patterns referenced to a single datum (finish-bored center bore). Threaded holes held to 6H class accuracy using rigid tapping with specialized thread mills. Clearance holes reamed to H7 class for consistent fastener fit. Inner and outer hole arrays maintained coaxiality ≤0.015mm through single-setup referencing.
• Micro Side-Hole Chip Evacuation: Small-diameter side holes presented chip evacuation challenges — addressed through high-pressure coolant-through tooling (≥30 bar) with peck-drilling cycles to break chips and prevent clogging in confined geometries.
• Anodizing Dimensional Control: Hard anodizing adds 10-25μm coating thickness. Finishing allowances adjusted to account for coating growth, with final inspection after anodizing to confirm dimensions remain within tolerance.

Quality Verification

CMM inspection verified step parallelism (≤0.01mm), multi-hole positional accuracy (±0.015mm), and hole pattern coaxiality (≤0.015mm). Thread gauges confirmed 6H class compliance. Surface roughness verified at Ra≤1.6μm. Anodized coating thickness measured at 10-25μm per MIL-A-8625 Type III specification, with matte silver color consistency verified.

Industry Applications

Ideal for medical imaging equipment adapter flanges, precision instrument mounting interfaces, diagnostic imaging system components, and high-tolerance structural adapters.

Why Partner With Us?

• Proven expertise in turn-mill single-setup machining for parallelism-critical flanges
• Precision hole making for threaded 6H and clearance H7 class features
• In-house matte silver hard anodizing with MIL-spec compliance
• 12+ years of precision manufacturing experience across medical imaging and diagnostic equipment sectors