Plastic Air Exhaust Duct

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Plastic Air Exhaust Duct

Processes: 
Sectioning and CNC Machining
Materials: 
Natural (Milky White) ABS
Finishing: 
Raw Smooth (Sanding Smooth)
Lead Time: 
4 days
Requirement: 
DFM + Machining + Splicing/Assembly + Inspection

Step 1: Product Presentation

The first step in our operating procedure is to receive and evaluate the file to enable us recommend the ideal machining method for the client’s needs.

In the case of this product, there was an evaluation of a 3-axis machining method. The evaluation found that the 4 runner holes cannot be perfectly machined to follow the models. The report also showed some blind areas that cannot be accessed with cutters. 

In line with these situations, the next step is to proceed to present alternatives.

Alternatives include splitting the part in several sections, machine and then glue to a unit. Another option is to employ 5-axis machining procedure.

Both alternatives are then provided to the client with an outline to compare for references. A comparison table for both alternatives is detailed below: 

Method

Lead Time

Cost

Air Tight

Strength

Five-axis Machining

Long

Very High

Good

Excellent

Section for Machining

Short

Low

Can be controlled and test

Good

 

After communicating these alternatives with the client, we take their considerations into making an intake manifold runner for the design prototype. The client then concludes on the sectioning for machine proposal due to the considering of flexible lead-time and low cost of operation. Having reached a conclusion, the next step is to begin the next phase for design proposal. 

Step 2: Sectioning Design Proposal

Before proceeding to machine, it is imperative that we make a sectioning plan for the evaluation of the client. This plan is then sent to the client to gather thoughts and raise impressions. Since quality is our watchword, we strive to carry our clients along and make them satisfied every time.

The following pictures shows our section plan. As seen in the image, we have divided the parts into 2 upper and 2 lower bases. The runner holes have also been separated into 2 halves to enable the inner face of the product to be machined accurately.

Considering the fact that the product is divided into several pieces, we elected to add some connecting hooks to ensure better location and strengthening of the entire structure as indicated in the small tips below. 

On receiving a positive response and go-ahead from our client, the next step is to transform the layout and idea into a real physical product with machining. 

Step 3: Machining the individual units

This is well the real work begins. To begin the machining, we proceed by following the sectioning design proposal to machine the individual parts as projected by the 3-axis machine.

Another benefit of electing to section the parts lies in the fact that we can reduce the machining difficulty by making the parts easier for machining.

cnc machiningcnc machining
cnc machiningcnc machining parts

During the process, we had parts injected and tested, and had the tooling modified accordingly to make the high quality parts.

Step 4: Gluing The Joints

After machining the individual units into a single piece, we ensure rigidity and a solid design by using industry-standard glue for jointing. This part is made easy and will be fixed more accurately since we added some dovetails feature for locating during the sectioning phase. 

cnc machining partcnc machining part

Step 5: Hand-finishing and Inspection

The final part of the project is the hand-finish and inspection part.

We must await the solidification of the glue before evaluating. Once we are ready, we add some hand-finishing to beautify the product. The last step is inspection.

During inspection, we check for missed features if any and tally the dimensions to ensure it meets the client’s design specifications.

Finally, we evaluated the strength of the unit as that represents a primary concern for most clients and completed several other units without any problems. 

 

At First Part, we go to great lengths to ensure that all our clients are satisfied. Our wide array of services include rapid prototype, plastic injection molding and CNC machining. We believe in the need for constant innovation and projects as a panacea for improving our CNC machining capability and sharping our thoughts for engineering. 

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