Prototype for electrical fitness machine

Services: CNC milling and turning, anodizing, blackening, powder coating
Material: Aluminum 6061-T6, steel C45
Qty: one set with 50 components

About the project

This is a European customer that manufactures and sells electronic fitness machines for a global market. They mainly focus on the industry of electric motor driven equipment for neuromuscular testing and training for sports and rehabilitation. They was in the stage of designing a new version of their product and need the prototype to verify their design, so our team was approached to help them produce most of parts of the prototype.

About the product

This is a training device used for assisted/resisted running. This machine is mainly composed of a small DC motor in the middle, a main PCB on the left side which controls the motor and a batteries as well as a charger/power supply on the right side.

Analysis of part drawing and assembly drawing

Before we get the production started, our engineer carefully review all the technical drawing and 3D files that are provided by our customers, understand the parts’ functional requirements and analyze if the technical requirements is reasonable and appropriate for CNC machining, then provide the according solutions for customer to choose.

The following is one of the technical discussions with the customer

We found some parts have 90 degree inside corners from the customer’s CAD file, but in reality the cutting tool that we use is rounded, it is impossible to cut out the sharp inside right corners by CNC machining. We discussed the possible solution with the customer and they agreed modify the sharp to the radius of 2mm.

Some inside sharp corners need to be modified

CNC Machining

CNC milling and turning is the main process used to make the steel and aluminum parts of this training device. Each part was made by using the tools and CNC machine to meet the required dimensions and tolerances.
Milling is a machining process which use rotating rotating multi-point cutting tools to remove material from the workpiece. The CNC machine typically feeds the workpiece to the cutting tool in the same direction as the cutting tool’s rotation.
Turning is is a machining process which employs single-point cutting tools to remove material from the rotating workpiece. In CNC turning, the CNC machine—typically a lathe or turning machine—feeds the cutting tool in a linear motion along the surface of the rotating workpiece, removing material around the circumference until the desired diameter is achieved.

The finished parts

Inspection and assembly testing

After the we finished the CNC machining and surface treatment, our inspection department inspect the parts carefully to make sure they meet the desired specifications, tolerances, and surface finish.
We also did some testing by simply assembling some of the parts that have tight tolerances to confirm the individual components can fit each other.

Customer’s feedback

Once the finished parts arrived, the customer assembled all the parts together and added some extra hardware to make a completed set. Delightedly, everything works well and the testing for the function is successful, they shared this good news to us and showed us the assembly through the photos.
We are so glad that we could help our customer with their project. If you have the same demand, please send your CAD drawing and we will provide you a free quote and project review.