Custom Aluminum

Standard Capabilities:

• Maximum Part Size: Up to 2000mm x 800mm x 600mm

• Minimum Feature Size: 0.5mm with proper tool selection

• Tolerance Range: ±0.005mm (±0.0002 inches) on critical features

• Maximum Part Weight: 500kg single component

• Surface Roughness: Ra 0.8μm achievable as-machined

• Production Volume: 1 to 100,000+ parts

• Lead Time: Prototypes in 3-5 days, production in 10-20 working days

Machine Shop Equipment:

• 20+ CNC machining centers (3, 4, and 5-axis)

• 8 CNC turning centers with live tooling

• In-house EDM wire cutting and sinker EDM

• Coordinate Measuring Machine (CMM) inspection

• Surface and roundness testers

• Automated tool presetters

Quality Assurance:

• ISO 9001:2015 and AS9100D certified processes

• First Article Inspection (FAI) per AS9102

• In-process statistical process control (SPC)

• Full traceability from material certification to final inspection

• Mechanical testing and material validation capabilities

• Non-destructive testing (NDT) available upon request

Surface finishing of custom aluminum parts serves multiple purposes: corrosion protection, wear resistance, aesthetic enhancement, electrical conductivity, and preparation for subsequent operations. The appropriate finish depends on the application environment, functional requirements, and cost constraints.

Anodizing

Anodizing is an electrochemical process that converts the aluminum surface into a durable, corrosion-resistant aluminum oxide layer. Type II (conventional) anodizing produces a clear or colored oxide layer with moderate thickness, suitable for general protection and aesthetic applications. Hard anodizing (Type III) produces a thicker, denser oxide layer with enhanced wear resistance, commonly specified for moving contact surfaces and demanding environments. Clear anodizing preserves the natural aluminum appearance while providing protection. Color anodizing is available in black, gold, red, blue, and custom colors for decorative or identification purposes. Chromic acid anodizing produces a thin oxide layer with minimal fatigue impact, often specified for aerospace structural parts.

Chemical Conversion Coatings

Chemical conversion coatings, commonly known as Alodine or Iridite, produce a thin, conductive oxide layer that provides moderate corrosion protection without significantly affecting part dimensions. This finish is frequently specified for electronic applications where electrical conductivity must be maintained, and for parts that will receive paint or adhesive bonding. Chromate and non-chromate formulations are available to meet environmental and regulatory requirements.

Mechanical Finishes

Bead blasting produces a uniform matte surface texture using glass or ceramic media. It removes tool marks and provides a consistent appearance for subsequent anodizing. Brushing creates a directional grain pattern on flat or contoured surfaces, commonly used for architectural and consumer product applications where a decorative finish is desired. Polishing produces a reflective, high-gloss surface achieved through progressive abrasion. Tumbling and mass finishing use vibratory media to remove burrs, radius edges, and improve surface uniformity on large quantities of parts.

Coating and Plating

Powder coating applies a dry polymer powder that is cured to form a durable, decorative finish. It is available in a wide range of colors and textures, providing excellent corrosion resistance for exterior and high-contact applications. Electroless nickel plating deposits a uniform nickel-phosphorus coating on aluminum parts through an auto-catalytic process. It provides hardness, wear resistance, and corrosion protection on complex geometries. PTFE (Teflon) coatings reduce friction and provide non-stick surfaces for sliding or sealing applications. Ceramic coatings offer high-temperature resistance and hardness for specialized industrial applications.

Application Guidelines by Finish

The choice of finish should be guided by the specific application. Aerospace exterior parts generally specify hard anodizing or chromic acid anodizing. Medical devices require finishes that are biocompatible, cleanable, and resistant to sterilization processes—electropolishing and clear passivation are common choices. Consumer-visible parts often use brushed or polished finishes with clear anodizing for protection. High-wear components benefit from hard anodizing (Type III) to extend service life. Electrical applications specify chemical conversion coating to maintain conductivity. Outdoor and marine equipment requires powder coating or e-coating to resist corrosion in harsh environments.