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.