Portfolios on Astro Manufacturing & Design

Services Machining Services Fabricating Services Plastics Electrical Discharge Machining Painting Automation Systems Assembly Rapid Prototyping Cable Assemblies &
Wire Harnesses Inspection Portfolios Vacuum Formed Plastic Parts
for Vehicles and Trucks 5 Axis Routing of Plastic Components Left Ventricular Assist Device as an Alternate Heart Pump Machining for a Four Level Cervical Spinal Fixation Plate Aircraft Component Housing Stamping Die Prototype Forming Die EDM'ing Large Quantity
Production EDM Medical Imaging Systems
for Components Medical Imaging System for
Integration and Assembly Missile Internal Component
Housing for the Military


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		Vacuum Formed Plastic Parts for Vehicles and Trucks Using high-strength UV stable plastic, we vacuum formed plastic components for use in automotive applications. Tight tolerances were held and the components were manufactured to meet EPA emission control requirements. The color was selected to match the specific application. The final plastic formed parts are heat-resistant, and can withstand an engine’s high temperatures.




		5 Axis Routing of Plastic Components In order to create 5 axis routing of plastic components, we used several different processes. First, we employed 5 axis machining, and then we custom manufactured vacuum fixtures for work holding. CAM programming was an essential part of the project, and the customer supplied CAD models and prints. The work holding fixture was designed on site. Upon completion, the 5 axis routing of plastic components measured 5 feet long, 10 feet wide, and 3 feet tall.




		Left Ventricular Assist Device as an Alternate Heart Pump Made from one piece of titanium, this LVAD heart pump was designed for orthopedic and cardiovascular applications. Several steps were involved in manufacturing the device, most notably 5 axis machining and efficiency optimization, in which we vertically integrated manufacturing processes, fit and fill, function ability, and cost control. The component received proprietary polish to minimize turbidity and propensity, and featured fluidity and stability upon completion. The final LVAD heart pump was ISO 13485 certified to meet industry standards.




		Machining for a Four Level Cervical Spinal Fixation Plate This four level cervical spinal fixation plate was manufactured from titanium. Applied printing processes were used to machine the component, including 5 axis milling with 40,000 RPM spindle speed, and the custom manufacturing of the fixture. The spinal fixation plate received a high micro finish, and was ISO 13485 certified to meet medical industry requirements.




		Aircraft Component Housing To manufacture this aircraft component housing, designed for use in the aerospace industry, we used several CNC milling and turning processes. The primary material was mild steel tubing, Grade MT1010. Slotting, counter boring, and radius machining were applied using CNC milling, and seventy degree angles were achieved. Drilling, countersinking, and tapping were executed using CNC turning. Tight tolerances (+/- .0008”) were upheld throughout the manufacturing process. Next, secondary processes were carried out, including deburring, the installation of 8/32” screws, heat treatment, and in-process inspection using CMM. The final component was 4.100” long (+/- .005”) and 5.993” in diameter. In total, 20-50 aircraft component housings were ...




		Stamping Die Prototype Using applied printing processes, we manufactured this stamping die prototype in one day. We compressed and welded 25 to 500 stacked pieces, and then EDM machined holes. All equipment was CAM programmed, and we upheld a tight tolerance of +/- .0002” throughout the process. Because of the nature of the process, modifications could be made on the fly. The material ranged from .002” to .025” in thickness, and upon completion, the stamping die prototype consisted of 1” to 10” long squares.




		Forming Die Electrical Discharge Machining This forming die was manufactured using a RAM EDM machine with CNC control. To form the hardened steel, several applied printing processes were applied. First, we CNC machined and grinded the graphite electrode, and then we used EDM to die-form plunge into the material. We created EDM start holes to join the two halves of the die together, and then EDM machined dowel holes into the die. The steel was 12” in thickness. Upon completion, the final forming die was 20” long and 30” wide.




		Large Quantity Production EDM We employed EDM machining to manufacturing this large production quantity.




		Medical Imaging System for Components Using a PEM insertion machine with a feeder bowl along with other equipment, we used a range of applied printing processes to create this medical imaging system for military use. Working with 1008 low carbon steel, A36 steel, 304-2b stainless steel, 5052-H32 aluminum, and 6061-T6 aluminum, we first conducted PEM nut insertion. Next, we used CNC machining to execute laser cutting, water jet cutting, and to manufacture the press brake and gantry mill. We also conducted MIG and TIG welding, general machining, and custom figure manufacturing. Material thickness ranged from .062” to .500”, and all work was done from a solid works and pro-engineer drawing type.




		Medical Imaging System for Integration and Assembly This project consisted of a variety of separate applied printing processes. The installation of scanning systems and radiographic systems required a 15,000 pound lifting capacity, along with medial peripheral installation, lead glass shield production, image testing, and basic machining and metal fabrication. We installed the imaging system into ISO shelters for USAF, US Navy, and US Army use, and the lead glass shielding was included to provide radiation protection.




		Missile Internal Component Housing for the Military To manufacture this aluminum missile internal component housing, we used CNC milling to conduct counter boring, chamfering, and boring. We upheld a +/-.001” tolerance throughout the process, with a +/- .004” perpendicularity tolerance. As a secondary operation, we deburred the component, then primed and coated it with mil-spec epoxy, followed by a mil-spec chem film coating. Both coatings met strict mil-spec standards. Upon completion, the missile internal component housing measured 14” long and featured a 9 foot casting diameter.