Manufacturing of an Aluminum Electrical Housing & Covers for the Military Electronics Industry

  • This Electrical housing required deep pocket machining ideal for our Mazak 4 Axis machining center.
  • This part was manufactured using unattended high speed spindle machining services.
  • We set up a production cell to run 24/7 for the duration of this project.
  • We designed and built a custom extrusion that could best utilize P & L Machines 4 axis machining center. This would reduce manufacturing time. That in the end would be cost effective to the customer.
  • We were the project manager for all mechanical parts. We delivered completed mechanical kits to the customer. This included sheet metal parts and all painted parts, along with all helicoils needed in housings & covers.
  • This part combined custom fixturing & tooling along with precision 4 axis machining, clear anodize coating & complete inspection with our new Zeiss coordinate measuring machine (CMM). Tolerances held on this project were held to .001".
  • Part material 6061-T6 Aluminum 5" X 5" X 4"
  • We manufactured this project from prototype to production (approx. 5000 pieces in 6 months).
Manufacturing of an Aluminum Electrical Housing & Covers Project Highlights
Project Name & Description
Electrical Housing & Covers
Capabilities Applied/Processes
Primary: Engineering: Process Development Custom Extrusion CNC Horizontal Milling
Secondary: Deburring Painting Chemical Conversion Coating Helicoil Insertion
Overall Part Dimensions
Length: 5 in. Width: 5 in. Height: 4 in.
Material Used
Material Finish
Painted: Chemical Conversion Finish
Industry for Use
Military Electronics
In Process Testing/Inspection Performed
Dimensional Inspection, Visual Inspection
5,000 pcs
Delivery/Turnaround Time
6 Month Project Timeline with Specified Deliveries
Delivery Location
Austin, TX
Standards Met
Customer Specifications, CAD Drawings
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