Custom CNC Machining Thin Wall Aluminum Enclosure Deep Pocket 0.01mm Precision Service

Dongguan Changxinda Precision Technology Co., Ltd. has been manufacturing custom non-standard precision parts since 2008 for buyers in medical equipment, robotics, automotive, aerospace, automation, laser, LED, lithium battery and precision testing instrument industries. Our shop floor runs 4-axis and 5-axis CNC machining centers, turn-mill combined lathes and high-speed milling spindles, and every order is handled by a dedicated project engineer from drawing review to final inspection. More than 200 customers worldwide, with 50 to 60 percent of output exported.

This custom CNC machining service covers thin wall aluminum enclosures machined from solid 6061-T6 or 7075 billet, with wall sections between 0.8 mm and 1.5 mm, deep rectangular pockets, tight corner radii and multiple datum faces. Because thin walls deflect, the enclosure is not simply programmed and cut. It is engineered as a process: the machining sequence, the workholding and the stress path are decided before the first chip is made.

Machining Process Flow

Every thin wall enclosure follows a documented seven stage route. Each stage is recorded in the job traveller, so the same parameters can be reproduced on repeat orders.

• Stage 1 - DFM review: our engineer checks wall thickness, pocket depth to width ratio, corner radii, thread callouts and datum strategy against our tooling library, then returns a marked-up drawing with cost-down proposals within 24 hours.
• Stage 2 - Billet preparation: saw cutting with 2 mm to 3 mm allowance per face, then face milling of all six sides to establish the reference cube.
• Stage 3 - Roughing: dynamic high-efficiency milling removes 60 to 70 percent of stock with constant chip load, keeping heat input low so residual stress is not driven into the thin walls.
• Stage 4 - Stress relief: rough machined parts are released and stabilised before finishing. For deep pocket enclosures this step alone removes most of the bow and twist that later shows up after anodizing.
• Stage 5 - Semi-finish and finish: 5-axis simultaneous machining with a high-speed spindle at up to 20,000 rpm, small radial depth of cut and light finishing passes on the walls to hold 0.8 mm sections without chatter.
• Stage 6 - Workholding: vacuum fixture plates with dedicated sealing grooves, plus low melting point alloy or expanding supports inside the cavity where the pocket is deeper than 4 times the wall thickness.
• Stage 7 - Inspection and packing: CMM measurement against the drawing datum scheme, first article report issued with the shipment, parts packed in foam partitioned export cartons.

Precision and Inspection

Tolerance is held at plus or minus 0.01 mm on critical features, with wall thickness variation within 0.02 mm, flatness 0.02 mm per 100 mm and surface roughness Ra 0.8 on machined faces. Position tolerance on mounting holes is controlled to 0.015 mm so that mating covers and PCB stacks assemble without reaming.

• Temperature controlled metrology room at 20 degrees Celsius, CMM resolution 0.001 mm
• First article inspection report with 12 to 20 measured dimensions and a ballooned drawing
• In-process checks at stage 4 and stage 5, not only at final inspection
• Optional roughness tester trace, hardness check and anodized coating thickness report
• Data pack delivered as PDF or Excel, part photos available on request

Non-Standard Customization

We work to your drawing, not to our catalogue. There is no standard part number to force your design into.

• Any input format: STEP, IGES, X_T, DWG, DXF, PDF, or a physical sample for reverse engineering
• Prototype from 1 piece, no tooling charge, no minimum order quantity
• Material options: 6061-T6, 7075-T6, 5083, 2024, plus 304 and 316L stainless steel when the enclosure needs corrosion resistance
• Surface options: clear or black anodizing, hard anodizing, bead blasting, sand blasting, laser marking, chromate free conversion coating
• Design changes handled at any stage before finishing, with the cost impact confirmed in writing first

Delivery and Capacity

Stable delivery is a production planning problem, not a promise. We quote a date that our schedule can actually hold.

• 1 to 10 pieces: 3 to 7 working days after drawing approval
• 11 to 100 pieces: 7 to 14 working days
• Mass production above 100 pieces: 14 to 30 working days depending on complexity
• Repeat orders keep a reserved capacity slot, so lead time does not drift order after order
• Weekly progress update with WIP photos, and an immediate notice if anything risks the ship date
• Express, air and sea freight, door to door delivery available, export documents prepared in house

FAQ

Can you machine an enclosure with 1 mm walls and 60 mm deep pockets?

Yes. Depth to wall thickness ratio up to 50 to 1 is within our process window when the pocket is open on one side and a support medium can be used. Send the drawing and we will confirm the route and any design change needed.

How do you prevent the part from warping after anodizing?

By finishing after stress relief, by keeping equal stock removal on both sides of the wall, and by specifying the anodizing rack position with our coating partner. Thin wall enclosures are also measured before and after coating on first article.

Do you sign an NDA before quoting?

Yes, we can sign your NDA or provide ours. Drawings are stored on a restricted server and are never shared with third parties.

What do you need to quote?

A 2D PDF drawing with tolerances plus a 3D model if available, material, quantity, surface finish and target delivery date. Quotation is normally returned within 24 to 48 hours.