We machine aluminum intake manifolds on 16 simultaneous 5-axis centers. Runner profiles, flange faces, and injector bores hold to ±0.005 mm, then anodized for corrosion resistance. From one prototype to 10,000+ parts.
Most failures trace back to one of these four issues. Each one costs a rework cycle or a scrapped casting.
If the runner volume varies between ports, cylinders run lean or rich and the ECU trims fight each other. Hand blending cannot hold a profile. We cut each runner with a ball-nose tool on a 5-axis center and verify the cross-section so all ports match within the tolerance band you set.
A flange that is not flat within 0.05 mm will not seal against a gasket at 1.5 bar. Warping shows up after heat cycles when the part was machined without stress relief. We rough, stress-relieve, then finish the mating face in a single setup to keep flatness where it needs to be.
A bore that is 0.1 mm off axis changes the spray pattern and can cause a misfire code. The tolerance on injector bore position is tight for a reason. We locate these features from the same datum as the flange, so the bore-to-flange relationship stays consistent from part one to part 10,000.
Type II anodizing builds 5–25 μm per surface. On a bore with a ±0.01 mm tolerance, that build can push the part out of spec. We mask critical bores and threads before anodizing, or machine to a pre-anodize dimension that accounts for the coating thickness. Either way, the finished part measures to print.
The manifold goes from billet or casting to anodized part without losing its reference points.
An intake manifold is a geometry problem. The runners curve in three dimensions, the plenum floor is not flat, and the flange bolt pattern has to line up with the head. Moving the part between setups adds error every time it is re-clamped.
Our 16 simultaneous 5-axis centers hold the part in one fixture and cut the runners, plenum, and flange without re-chucking. Positional tolerance stays at ±0.005 mm across all features because they share one datum.
Most manifolds we cut are 6061-T6 or 6063 for billet builds and ADC12 for castings that need finish machining. 6061-T6 gives the best mix of machinability and strength for boosted applications. 7075 is available when the flange sees high bolt loads, though it anodizes to a darker tone.
Anodizing happens in-house, so the coating thickness is set before the finish pass. Clear, black, and hardcoat are all available. We mask injector bores, sensor threads, and gasket faces so the anodic layer does not change a fit that has to stay within tolerance.
Pick the grade based on how the part is made and what it has to survive.
| Grade | Best for | Notes |
|---|---|---|
| 6061-T6 | Billet manifolds, boosted engines | Easy to machine, anodizes clean |
| 6063 | Billet manifolds, NA engines | Better finish, lower strength |
| 7075 | High bolt-load flanges | Stronger, darker anodized tone |
| ADC12 | Cast manifolds, finish machining | Near-net shape, less stock removal |
| 5052 | Sheet-metal plenums and covers | Formable, weldable, good corrosion |
One shop for the whole part, from prototype to production.
Simultaneous 5-axis centers cut runners, plenums, and flanges in one setup. Ø400 mm rotary table and travels up to 4,000 mm handle large plenum volumes.
3-axis and 4-axis mills for flange faces, bolt patterns, and sensor bosses. Mill-turn centers handle injector bungs and fittings in the same cycle.
First-article manifolds cut from billet in days, not weeks. Use the prototype to check fit on the head before committing to a casting.
Anodizing, bead blasting, and polishing in-house. Clear, black, hardcoat, and conductive anodizing with masking on critical features.
Runs from one part to 10,000+. Fixtures and programs are kept on file so repeat orders skip the setup phase.
100% inspection before shipment. Raw material certs, in-process checks, and final dimensional reports available on request.
Numbers that decide whether your manifold fits on our floor.
| Parameter | Range | Applies to |
|---|---|---|
| Tolerance | ±0.005 mm (±0.0002 in) | Critical bores and flange faces |
| Runner finish | Ra 0.8–1.6 μm | As-machined airflow surfaces |
| Max part size | 4,000 × 400 × 150 mm | Large plenum and log manifolds |
| 5-axis travels | 750 × 1,150 × 550 mm | Most V8 and inline-6 manifolds |
| Rotary table | Ø400 mm | Curved runner indexing |
| Min order | No minimum | One prototype to 10,000+ parts |
The numbers behind the parts.
Fifteen years cutting aluminum, steel, and titanium for automotive and industrial customers. The process knowledge is in the fixtures and the tool paths, not a brochure.
16 five-axis, 12 four-axis, 27 three-axis, and 16 mill-turn centers. Capacity is spread across three wholly-owned plants covering 7,600 m².
Held on bores, flange faces, and runner profiles. Inspected with CMM and on-machine probing. Reports available with each shipment.
Send a STEP file and get a quotation plus a free DFM analysis within 12 hours. Production can start within 24 hours of approval.
Parts that pass final inspection the first time. Raw material check, in-process monitoring, and 100% final inspection before shipment.
Also ISO 9001:2015, ISO 13485:2016, and ISO 27001:2022. Automotive quality management is the default, not an add-on.
Cut from 6061-T6 plate for boosted builds where a casting would need thick walls.
Single-piece runner and plenum sections for flow-bench testing before tooling is cut.
Masked bores and threads keep anodic build off features that must stay within tolerance.
Machined and formed covers that bolt to the manifold body with a flat sealing face.
Send a STEP or IGES file with the flange datum and critical features marked. A 2D drawing helps define tolerances on bores and flange faces that the 3D model does not spell out.
If the part is a casting that needs finish machining, include the as-cast model as well. We check stock allowance against the finished geometry before quoting.
Yes. There is no minimum order quantity. A single billet manifold can be cut and shipped in 3–5 days once the program is proven.
Most customers use the first part to check flange fit and runner clearance on the engine before ordering a production batch.
Type II anodizing builds roughly 5–25 μm per surface. On a bore with a ±0.01 mm tolerance, that build matters.
We mask injector bores, sensor threads, and gasket faces before anodizing, or machine to a pre-coat dimension that leaves room for the coating. The finished part is measured after coating, not before.
6061-T6 is the default for billet manifolds on boosted engines. It machines well, takes anodizing evenly, and has enough strength for typical boost pressures.
7075 is an option when the flange sees high bolt loads or the part needs maximum strength, but it anodizes to a darker color and costs more.
Each runner is cut with a ball-nose tool on a 5-axis center. The tool path follows the intended centerline, and the cross-section is checked against the model at several points along the runner.
On-machine probing verifies position before the part comes off the fixture. All runners share one datum, so port-to-port variation stays inside the tolerance band.
Yes. Send the casting model and the finished part model. We check stock allowance and set up the fixture to locate from the as-cast datums.
Flange faces, bores, and bolt patterns are cut in one setup where possible. If the casting needs stress relief before finishing, we say so in the DFM report.
Every shipment gets a raw material check and a final dimensional inspection. Reports are available on request, including CMM results on critical features.
If your quality team needs specific data points documented, tell us at the quote stage so the inspection plan covers them.
Uploads are secure and confidential. We can sign an NDA before you send files if your design is not yet public.
Your CAD files and fixtures are not shared with other customers. Programs and fixtures are kept on file only for your repeat orders.
Upload a STEP file and we will return a price, a DFM analysis, and a lead time. No minimum order quantity.
12-hour quote100% inspectionNo MOQNDA on request
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Upload your 3D model or 2D drawing and get a quotation with a free DFM analysis. Maximum processing size 4,000 mm.
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