Five-Axis 7075 Aluminum Optical Housing

Engineering challenge

The 7075 aluminum housing contained deep, open cavities and required substantial material removal. Stress release could move the remaining walls, and repeated setups could accumulate alignment error. Although the original model was theoretically workable, first-part assembly exposed an interference condition.

This made the first physical build an engineering feedback step as well as a machining task. The remaining wall structure, setup count and critical assembly interfaces all had to be reviewed together before the revised part could proceed.

Manufacturing approach

The project began with a DFM review and a revised machining sequence. A controlled roughing strategy and retained finishing allowance were used to manage the high material removal, while the fixture plan reduced unnecessary re-clamping of the hollow housing.

Critical interfaces were checked with CMM inspection between process stages. Feedback from the first physical part was used to correct the assembly interference before the final prototype housing was completed.

Recorded project outcome

The assembly interference was resolved through the revised manufacturing approach. The finished component passed the recorded drawing checks and was accepted for prototype assembly and testing.