5-axis machined intake, exhaust, hydraulic and pneumatic manifolds from aluminum, stainless and titanium. Port faces, seal grooves and mounting holes held to ±0.005 mm, with traceable inspection records and 3-5 day shipping on repeat runs.
Manifolds are judged by how they seal and flow, not by how they look on a bench.
A manifold face that is out of flat by 0.03 mm will leak under 10 bar, no matter how tight the bolts are. Gasket compression cannot compensate for a bowed face. We measure flatness on the sealing surface before the part leaves the machine, not after the customer finds a drip.
Internal channels intersect at compound angles. A drill that enters 0.2 mm off can break into the wall or leave a burr that restricts flow. When the intersection is wrong, the whole casting or billet is scrap. Five-axis positioning and in-process probing keep the intersections where the drawing puts them.
Hardcoat anodizing builds 25-50 μm per surface. A thread or slip fit that was correct after machining will not assemble after coating. We mask sealing faces and threads, or cut them after finishing, so the coating does not close the tolerance you paid for.
When a manifold fails leak test on the assembly line, the first question is whether it was ever measured. A CMM report with the serial number attached answers that in minutes. Without it, you are re-checking a whole lot by hand and delaying the build.
Most manifold defects come from repositioning the part between operations.
A manifold has features on every face. If you machine it in three operations on a three-axis mill, each move adds a datum shift. We cut the port faces, the mounting pad and the internal passages with five-axis simultaneous motion, so four or five faces come off the same zero point.
That matters most where a port centerline has to meet a mounting hole at a compound angle. One datum keeps the relationship between them inside ±0.005 mm instead of stacking three separate errors.
Intake manifolds usually run 6061-T6 or 6082 for weldability and weight. Hydraulic manifolds often need 7075 or 17-4PH where pressure cycles are high. Exhaust-side parts move to stainless or Inconel when surface temperature climbs past what aluminum tolerates.
Passage geometry drives the toolpath. Long straight bores get drilled and reamed for surface finish. Short angled intersections get ball-nose cut with a radius that a tool can actually reach. We flag any internal corner tighter than the cutter can produce during DFM, before the first chip is cut.
Process choice follows passage geometry, batch size and sealing requirements.
| Part condition | Recommended route | Why |
|---|---|---|
| Straight drilled passages, 2-3 faces | 3-axis milling + drilling | Lowest cost when datums stay simple |
| Compound-angle ports, 4+ faces | 5-axis simultaneous | One setup holds port-to-hole position |
| Round body with radial ports | Mill-turn center | Turning and radial drilling in one cycle |
| Thin walls, high finish | 5-axis + fine finishing | Ra 0.2–0.8 μm on sealing faces |
| Prototype, 1-5 pieces | 5-axis, no tooling | No minimum order, no fixture cost |
| 10,000+ parts per year | 5-axis + dedicated fixture | Repeatable cycle time, lower unit cost |
Machining is the core. These services support it from prototype to finished part.
Simultaneous five-axis cutting for manifolds with ports on multiple faces. One datum, fewer setups, tighter position between features. Handles bodies up to 4,000 mm.
Three-axis and four-axis milling plus mill-turn centers for round manifolds with radial ports. Good fit for hydraulic blocks and valve bodies.
Single-piece manifolds for fit checks and flow testing before committing to a production run. Free DFM analysis comes back with the quote.
Anodizing, electroless nickel, black oxide and bead blasting. We mask sealing faces and threads so coating build does not close your tolerances.
For higher volumes where a cast body plus machined faces costs less than cutting from solid. We machine the critical features after casting.
Quick geometry checks on internal passage routing. Useful when you need to see whether a channel actually clears before cutting metal.
| Item | Capability | Notes |
|---|---|---|
| Tolerance | ±0.005 mm | On critical sealing and locating features |
| Surface finish | Ra 0.2–0.8 μm | Fine finish on gasket and O-ring faces |
| Maximum size | 4,000 mm | Longest dimension we can process |
| Materials | Aluminum, stainless, steel, copper, titanium | Full list available on request |
| Batch size | 1 to 10,000+ | No minimum order quantity |
| Inspection | 100% before shipment | Reports on request |
| Quote turnaround | 12 hours | Includes free DFM analysis |
| Production start | Within 24 hours | After drawing and material release |
Fifteen years of machining, three plants, and capacity that does not depend on one machine.
Fifteen years of production machining, with 150 technicians across three wholly-owned plants in Dongguan and Singapore.
Not a lab figure. Critical manifold features are cut and verified to ±0.005 mm (±0.0002 in) on the shop floor.
Sixteen five-axis centers, twelve four-axis mills, sixteen mill-turn centers and twenty-seven three-axis machines.
Parts that pass final inspection on the first submission, measured across production runs.
Below two percent across past orders. Schedules are quoted from real machine capacity, not optimism.
ISO 9001:2015, IATF 16949:2016, ISO 13485:2016 and ISO 27001:2022 cover quality, automotive, medical and data security.
Intake and coolant manifolds where port position and flatness drive sealing. Machined on five-axis with leak-checked faces.
Cross-drilled bodies in 7075 or 17-4PH. Passage intersections verified before finishing so flow paths stay clear.
Compact air manifolds for actuator banks. Light aluminum bodies with masked sealing faces after anodizing.
Larger manifold bodies up to 4,000 mm for machine tool and test-stand plumbing. One datum across multiple faces.
STEP or IGES for the solid model, plus a 2D drawing if tolerances and surface finishes are not already in the model. PDF drawings are fine.
If you only have a casting drawing, send that. We can quote machining on the cast features and flag anything that needs a model before cutting.
We verify passage intersections during machining, using in-process probing and air gauging where the geometry allows. For critical channels, we document the toolpath and the measured position of each intersection.
If a passage is fully enclosed after a cover is fitted, the inspection record is built before that step, not after.
Yes. We machine critical faces, ports and threads on cast bodies, leaving the cast surfaces where they do not seal or locate.
Send the casting drawing with the as-cast condition noted. We will tell you which features need a machining allowance and where the casting tolerance is too loose to hold the finished dimension.
We hold ±0.005 mm on critical sealing and locating features, with flatness controlled on the gasket face itself. Surface finish on those faces runs Ra 0.2–0.8 μm.
If your design calls for a face flatter than that, tell us at the quote stage. It may require a different finishing pass and a longer cycle.
We inspect dimensions and surface condition on 100 percent of parts before shipment, with reports available on request. Pressure testing is quoted as a separate operation when the drawing specifies a test pressure.
Tell us the working pressure and test medium at the quote stage so the test fixture can be planned with the machining sequence.
Hardcoat anodizing adds 25-50 μm per surface. That is enough to close a slip fit or bind a thread if nothing is masked.
We mask sealing faces and threaded holes, or cut those features after coating, so the finished part still assembles to the drawing.
There is no minimum order quantity. We machine single prototypes and production runs of 10,000 or more from the same process.
For a one-off manifold, five-axis machining avoids the cost of a dedicated fixture. For high volume, we build a fixture and reduce cycle time per part.
Quotation and free DFM analysis come back within 12 hours. Production can start within 24 hours after drawing release and material confirmation.
Repeat orders typically ship in 3-5 days. First articles depend on material availability, which we confirm in the quote.
Upload a STEP file and get a quote with DFM notes within 12 hours. No minimum order, and your files stay confidential.
12-hour quote100% inspectionNo minimum orderNDA on request
Trusted by engineers and manufacturers worldwide
Upload your 3D model or 2D drawing and get a quotation with a free DFM analysis. Maximum processing size 4,000 mm.
CNC Metals 13 grades
CNC Plastics 10 grades
Machines & processes 12 options
Surface & post-processing 10 options
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