AS 9100D – Boyer Machine & Tool

Complex Aluminum Suspension Part Milled in One Setup

Kevin Yaney — Fri, 14 Aug 2026 17:39:17 +0000

A truck manufacturer needed an aluminum component for a suspension system assembly. The part had a complex geometry that called for precise milling in order for the tight specifications to be met.

Boyer specializes in complicated parts that hold close tolerances. This part was milled in one setup and required multi-axis milling and turning. The part necessitated tight profile controls. This was accomplished with C-axis contouring to both the outside and inside profile of the part. Since the part was to fit into an assembly with other parts, the edges were chamfered at 45 degrees to take off the sharp edges and ensure a smooth fit.

In order to produce intricate parts in one setup, Boyer puts an emphasis on three critical operational pillars. First, they have the expertise to mill difficult designs. Their machine operators are skilled craftsmen with decades of experience and they have the technology to machine elaborate components from all kinds of metals and plastics. Second, their quality control lab tests the tolerances on each piece that is fabricated at Boyer. This thorough testing reduces waste and ensures the print specifications are met. Third, they put an emphasis on efficiency. That requires a production plan before the machine is turned on to eliminate waste and reduce downtime. It also eliminates the need to change the part over for multiple setups. This has led to a 98 percent on-time delivery of parts.

In this case, the customer received their suspension component on time and milled precisely to design. When you need a complex part manufactured, contact Boyer, where quality is standard.

17-4 Stainless Steel Aerospace Parts

Kevin Yaney — Thu, 09 Jul 2026 13:17:15 +0000

Boyer specializes in machining intricate part designs with complex metal alloys. This part was machined for an aerospace application. It was fabricated with 17-4 stainless steel. The part was produced with multi-axis Swiss machining. The part was designed to be threaded with a flat side milled into the tread. It also had a recessed inset cut into the inside of the shaft. The part was produced in one setup. Boyer has the fabrication machinery and facility to produce parts entirely in-house to keep projects on schedule and delivered on time.

However, it is one thing to have the equipment, but to know how to machine complex metals is crucial. Boyer’s expertise in the nuances of different metals makes a huge difference. In this case, 17-4 stainless is a martensitic alloy known for its exceptional hardness and tensile strength. Unlike other stainless-steel alloys, it can be heat treated, which traps carbon in the steel and causes it to be very hard and magnetic. Due to its durability and corrosion resistance, it is an excellent metal for medical instruments, high-stress industrial applications, chemical exposure, as well as high-performance engine and aviation parts. Boyer’s quality control lab tests and monitors each job as the parts are being produced.

In the end, this part was produced to design specification and on time. If you are in need of complex metal parts with sophisticated geometries, give Boyer a call, where quality is standard.

Precision Aerospace Plastic and Inconel Parts

Kevin Yaney — Tue, 09 Jun 2026 15:30:44 +0000

An aerospace manufacturer was in need of two very different parts. One was a plastic coupling with a very thin wall and six precise holes. The other was an Inconel with a complex design requiring multi-axis machining. The manufacturer turned to Boyer to machine both of these parts.

The plastic part had very tight specifications and needed to be produced by machining the piece rather than plastic molding. Boyer Swiss machines plastic parts when strict accuracy is needed. The wall of the part was very thin with six holes that were critical to the design. This is where Boyer’s expertise in machining plastics came into play. Plastics can overheat in the process and warp. Especially when you are turning such a thin wall, strict controls are needed to keep from damaging the parts. This part was tested in Boyer’s QC lab during the run to ensure the integrity of the part.

The Inconel part was also Swiss machined in-house by Boyer. Inconel is commonly used in high-stress and high-heat aeronautic design. It is a superalloy with very good strength and corrosion resistance. Like many other nickel-based superalloys, it can be difficult to machine. Boyer has the expertise and capability to handle complex metals and multi-axis designs. In this case, the part was threaded on both the inside and outside diameters. The inside also required a hex head socket. Boyer used a wire EDM to form the hex on the ID.

All the work on these two parts was completed in house, which kept these jobs on schedule rather than waiting for out-sourced production to be completed and shipped back to us. This allows Boyer to test the parts in our QC lab as the parts are being produced. This also increases efficiencies and speeds up delivery times.

In the end, Boyer was able to meet the customer’s demands for both plastic and Inconel parts. If you are dealing with complex parts – be it plastic or metal – turn to Boyer, where quality is standard.

Industrial Steel Star Component Machined in One Setup

Kevin Yaney — Thu, 30 Apr 2026 14:29:59 +0000

A manufacturer was in need of an industrial steel component. The part was geometrically complicated. It was designed with a 10-point star with cutaway flutes and a threaded center hole. It had very tight dimensional tolerances.

Boyer specializes in machining metal and plastic parts with difficult geometric dimensions. In this case, the part required multi-axis Swiss machining. That included both turning the part and milling it. Due to the complexities of the part, many CNC machine shops would use multiple setups to mill it. But to achieve the engineering fit required, Boyer machined the part in one setup despite the complicated form of the component. Since every new setup takes more time and wastes parts, Boyer uses its expertise in Swiss machining to produce complex parts with minimal waste and keen attention to detail in the design. Small, but critical tolerances are achieved with proven process and procedure milling techniques developed over the years at Boyer. We also have a state-of-the-art quality lab that inspects parts during production.

Boyer also specializes in high-end surface finishing. That was also important in this case. These parts were ultrasonically cleaned before being securely packaged and shipped to the customer.

Boyer’s single setup helps speed up the production process without compromising quality. If you are in need of complex metal or plastic components, contact Boyer, where quality is standard.

Dual-screw, A286 Stainless Steel Jet Engine Bolt

Kevin Yaney — Thu, 02 Apr 2026 15:16:00 +0000

An aeronautics OEM was in need of A286 stainless steel dual-screw bolts for a jet engine application. The angle of the screws was skewed to fasten parts at differing orientations. The part had to withstand the rigors of extreme heat and tensile force.

A286 stainless steel parts are used in heat and cold extremes. It can be used in cryogenic conditions as cold as -320 and as hot as 1,300 degrees F. It is oxidation resistant up to 1,500 degrees F. It is also an extremely hard alloy with excellent tensile strength. It is perfect for highly stressful conditions, like those of a jet engine.

A286 can also be difficult to machine. This is where Boyer’s experience in machining difficult metals and their understanding of metallurgical properties make a difference. In this case, the hardened superalloy was machined in one setup. But this part also had a difficult design, with shafts for the dual screws set at divergent positions. Boyer used multi-axis Swiss machining to accommodate the differing angles of the shafts and threads of the screws. The components were also completed with a highly polished finish. The parts were ultrasonically cleaned. Boyer cleans all of their parts before packaging and shipping them.

The customer was pleased with the A286 dual-screw bolt. In the end, they were supplied a complex part with superior tensile strength that could withstand extreme temperature stresses. For more information on machining complex metals and plastics, contact Boyer, where quality is standard.

Tiny Copper Fittings Machined with Wire EDM

Kevin Yaney — Fri, 27 Feb 2026 16:23:23 +0000

A customer needed small copper fittings finished with a very precise groove cut into the tongue of a cylindrical part.

Boyer Machine specializes in wire EDM fabrication. When a part has a very specific geometry, computer-aided wire EDM is used to get the exact detailed part, but also to provide a very clean finished surface.

However, you also have to consider the metallurgical nature of the part. Boyer has the expertise to machine many different metals. In this case, copper was used for the part. Copper is a soft metal and can be challenging to machine. It can easily become gummy and cause problems if you don’t understand how to machine it successfully. For that reason, many CNC shops will not accept copper parts. Boyer was able to successfully machine these fittings and provide the client with copper parts to the design specifications.

If you are looking for a fabrication solution for difficult metals, contact Boyer, where quality is standard.

Tiny Aeronautics Component Produced with Multi-axis Swiss Machining

Kevin Yaney — Mon, 12 Jan 2026 21:05:43 +0000

An aeronautics manufacturer was in need of a tiny stainless steel component. The part had an intricate design with a hexagon head and a tapered lip, a hole centered through the neck and a recessed base that needed to fit snugly with an adjoining part.

This stainless steel part was perfect for Boyer’s Swiss machining services. Boyer has the capability to machine multi-axis small parts with complex geometries. They also have the expertise to understand the metallurgical nature of the materials they are machining – 304 stainless steel in this situation. That expertise avoids delays and waste.

Boyer also has an extensive quality lab to ensure that rigid design specifications are met. Parts are inspected, tested and documented during the machining process. In this case, that included both the fit and finish of the part. This component was machined in one setup, inspected and cleaned before delivery.

If you are designing small metal or plastic parts, Boyer has the machining capabilities and expertise to produce the most complex parts. Their standard of quality and on-time delivery record makes Boyer the preferred machine shop for tiny, complex parts.

Cosmetically-critical Inconel Part

Kevin Yaney — Tue, 30 Dec 2025 19:14:40 +0000

An aeronautics manufacturer was in need of a part milled from Inconel. The part was a cylinder designed with a very thin wall and an intricate lip that had a channel to accommodate a separate fitting and a thicker tongue to lock it in place. The part was cosmetically critical and had to be produced without any marks or marring.

Complex nickel superalloys, such as Inconel, are used in high stress and high heat applications because of their superior tensile strength. It has excellent corrosion resistance, which makes it a preferred material for aeronautic applications where the parts are exposed to harsh ambient conditions. However, Inconel is difficult to machine. Many machine shops would refuse to mill this kind of project. However, Boyer specializes in machining intricate metals and plastics. All machining and milling services are performed in-house to ensure quality control of each part. Parts go through rigid quality testing and documentation during production.

The aesthetics of this part were also critical. Each part had to be finished without any marks, including fingerprints or smudges. Boyer has the expertise and machinery to accommodate requests for cosmetically-critical and clean parts.

If you are in need of the machining of intricate parts fabricated from complex metals, or if you need an enhanced finish for your parts, contact Boyer, where quality is standard.

Complex 316 Stainless Steel Part Produced in One Setup

Kevin Yaney — Tue, 18 Nov 2025 21:12:31 +0000

A manufacturer was in need of a 316 stainless steel part that worked in a fluid control machine. The part was complex, with multiple channels and counterbores. The tolerances were very tight.

Boyer Machine specializes in machining complicated and detailed metal parts to their print specifications. In this case, Boyer machined this fluid control part in one setup. That eliminated two crucial problems: waste and extended delivery time. By turning the part in one setup, they were able to maintain close quality control tolerances and reduce wasted parts. They also sped up production time by getting rid of numerous setups to perform multiple tasks. Boyer takes pride in their on-time delivery. That is accomplished with state-of-the-art equipment that can handle milling multi-axis parts made with complex metals and the expertise of the craftsmen who make up our workforce. All parts also go through rigorous quality control inspections to ensure they are built to specifications, then cleaned before being packaged and delivered.

For more information on machining complex parts with tight engineering requirements, contact Boyer, where quality is standard.