Continental Precision’s collaborative engineering and multi-axis machining excellence were key to achieving tight tolerances on intricate geometries.
PHOENIX, Ariz.—Continental Precision, Inc. (CPI) has long provided reliable manufacturing services to customers who require mission-critical parts at the highest quality standards.
The company, incorporated in 1972, specializes in 5-axis machining and quick turnaround of tight-tolerance parts. Today, it produces a variety of precision machined, specialty components used in industries from aerospace and defense, to automotive and medical.
In addition to 5-axis machining, Continental Precision provides heat treatment and surface finishing as required. Its services also include wire electrical discharge machining (wire EDM), sink EDM, and polishing, according to Continental Precision President Nawed Akhtar, and General Manager Joe Aune.
“For the aerospace industry, we machine complex precision parts from solid material or castings or forgings,” Aune said in an emailed response to Design-2-Part. “For automotive, we specialize in machining various parts for niche sports cars.” Those parts, he said, include knuckles, Bell housings, and control arms, as well as front and rear structural parts.
According to the company’s website, NASA’s now-retired Space Shuttle Program used parts and components manufactured by Continental Precision since the program’s inception. So, too, has the International Space Station, launched in 1998.
“Since the early 1980s, CPI has manufactured complex precision metal parts for gas generators, catapults, ballistic devices, and rocket motors,” the website stated.
Continental Precision is an AS9100D and ITAR registered manufacturer that employs about 15 people at its 12,000-square-foot manufacturing facility. The company recently brought a new DMG 5-Axis Machining Center and CNC lathe into its operations to increase its capacity.
“We can machine parts up to 0.0001-inch [tolerance] and in quantities from 1 to 100,000,” said Aune, describing Continental Precision as a “one-stop shop” capable of handling the entire process of obtaining finished parts.
One of the company’s customers, described as a “leading aerospace client,” approached Continental Precision to manufacture intricate components for a next-generation aircraft engine. Aune said that confidentiality agreements prohibited Continental Precision from disclosing specific details about the project. The application did, however, typify CPI’s commitment to “pushing the boundaries of precision machining to deliver innovative solutions” for its clients, he noted.
“Our team of skilled engineers collaborated closely with the client to understand the unique challenges of the project, ensuring a customized approach that aligned with their specifications. Close collaboration with the client allowed us to align our machining processes with their expectations, addressing challenges through a joint problem-solving approach,” Aune said.
The components had intricate geometries and tight tolerances, and because of their critical function within the engine assembly, they required high precision. Traditional machining methods had proven inadequate to achieve the intricate shapes and tight specifications demanded by the project.
But Continental Precision was able to leverage its state-of-the-art 5-axis machining capabilities to develop “a tailored solution that allowed for simultaneous machining on multiple axes,” according to Aune.
“This capability enabled us to address the intricate contours and angles required by the aerospace components, surpassing the limitations of traditional machining methods,” he explained. “By harnessing advanced 5-axis machining technology, our team achieved unparalleled precision in simultaneous multi-axis machining, reducing setup times and ensuring that intricate geometries met tight tolerances.”
Both Aune and Akhtar agreed that Continental Precision’s success in addressing the aerospace manufacturing challenge stems from the adept application of its services and cutting-edge manufacturing processes.
“Adaptive manufacturing strategies, led by our engineers, dynamically optimized processes,” Aune said. “The project’s success underscored our ability to navigate and conquer technical challenges in manufacturing, showcasing the versatility and effectiveness of our advanced machining capabilities.”
In addition to its collaborative engineering approach and 5-axis machining excellence, CPI’s team employed customized toolpath strategies, real-time monitoring and quality assurance, and iterative prototyping for optimal results.
According to Aune and Akhtar, CPI’s tailored toolpath strategies optimized cutting parameters, delivering high precision and meeting the project’s demanding specifications. Continuous real-time monitoring systems ensured immediate detection of any deviations, enabling prompt adjustments to maintain the highest quality standards. And the team’s iterative prototyping and testing approach validated the machining processes, minimizing rework and ensuring the timely delivery of top-quality aerospace components.
“This integrated strategy highlights our commitment to precision, innovation, and client satisfaction in overcoming technical challenges,” Akhtar said.