We machine aluminum shell sets for humanoid robot prototypes: torso panels, limb covers, joint housings and sensor brackets. Tight tolerances, thin walls held flat, functional fits on the first build.
Four failures we see on humanoid programs before the first walk test.
A shell is machined to nominal, then coated. If the coating build is not planned into the bore and thread callouts, mating pins and fasteners no longer fit. The shell set is scrapped and the assembly schedule slips.
A 2 mm aluminum cover plate looks simple on a drawing. Clamp it on a vise and it deflects. The bore goes oval, the mating face rocks, and the joint housing no longer sits flat against the frame.
Deep contoured shells need tool reach and stiffness at the same time. Thin walls chatter, the surface tears, and the wall thickness varies enough that the shell flexes under servo load.
The first prototype doubles as a presentation unit. Visible stepover marks, burrs at the flange edge, or a mismatched anodized batch means the shell cannot leave the lab.
Fixturing, toolpath and finishing planned together so the prototype fits the frame.
Humanoid shells rarely present flat faces. Torso covers blend into shoulder radii, joint housings wrap around the actuator, and sensor brackets sit on compound angles. Repositioning a part four or five times adds stack-up error and hand-finishing time.
We program these shells on 16 simultaneous 5-axis machining centers with a Ø400 mm rotary table. One setup reaches most of the outer surface, so datums stay referenced to the same bore. The result is a shell that bolts to the frame without shimming or reaming at assembly.
Thin aluminum covers are the parts that decide whether a prototype walks or sits on a bench. Cutting forces push the wall away from the tool, and the finished panel springs back once the clamps release.
We control this with light radial cuts, high spindle speed, and supports built into the fixture rather than into the part. Ribs and flanges are left until after the thin web is finished. Wall thickness is checked on the bench before the shell leaves the cell.
Pick by stiffness, weight and finish, not by habit.
| Grade | Typical shell use | Why it works |
|---|---|---|
| 6061-T6 | Torso panels, brackets | Balanced strength, welds and anodizes cleanly |
| 7075 | Joint housings, load paths | High strength, machines to thin sections |
| 6082 | Structural covers | Good corrosion resistance, clean anodized look |
| 2024 | High-stress mounts | Strong in fatigue, needs coating protection |
| 5052 | Large flat covers | Formable, resists corrosion, low cost |
| ADC12 | Die-cast follow-on parts | Bridges prototype to production volumes |
Shells, brackets and fixtures from the same shop, so tolerances stay consistent.
Contoured shells, joint housings and compound-angle brackets cut in one setup on 16 simultaneous 5-axis centers.
Mill-turn centers handle housings that need both a turned bore and a milled flange.
Aluminum prototypes from single parts up, with DFM feedback before the first chip is cut.
Anodizing, bead blasting, brushing and laser marking, with coating build planned into the callouts.
Flat covers and mounting plates when a machined panel is more cost than the function needs.
100% inspection before shipment, with dimensional reports on request.
From file review to packed parts.
| Stage | What you get |
|---|---|
| File review | Quotation and free DFM analysis within 12 hours |
| Setup | Production can start within 24 hours of approval |
| Machining | 127 high-precision CNC machines across 3 plants |
| Finishing | Anodizing, plating, powder coating, bead blasting |
| Inspection | Raw material check, in-process monitoring, final inspection |
| Shipping | Parts ship in 3–5 days, uploads kept confidential |
Capability stated as data, not adjectives.
Founded in 2011, working from prototype runs into production volumes.
Metric and ±0.0002 in, verified on the bench before shipment.
16 five-axis, 12 four-axis, 27 three-axis and 16 mill-turn centers.
Dongguan, China and a Singapore factory at Joo Koon Circle.
Programmers, machinists and inspectors on staff, not outsourced.
100% inspection before shipment, reports on request.
Shell sets, joint housings, actuator brackets and sensor mounts.
Brackets and housings where weight and stiffness both matter.
One prototype to 10,000+ part runs on the same program.
Machined panels and covers that double as presentation units.
Start with 6061-T6 for torso panels and general covers. It machines cleanly, anodizes evenly and keeps cost predictable.
Move to 7075 when a joint housing carries load through a thin section. It is stronger but costs more and needs tighter tool control. Use 5052 for large flat covers that see little stress.
Yes, when the feature is machined in the same setup as its datum. Contoured surfaces that are repositioned between operations accumulate error, so we plan the fixture around the critical faces.
We confirm which dimensions carry the fit and which are cosmetic, then inspect the ones that matter. Sending a marked-up drawing speeds this up.
We machine aluminum walls from 1.2 mm when the geometry supports them. Deeper unsupported walls below that move under cutting force and tend to spring back after clamping.
If your design needs thinner sections, add a rib or a flange. We will flag it in the DFM review rather than cut a part that will not hold shape.
Yes. Anodizing builds a layer on the surface, and hardcoat builds more than a clear coat. Bores and threads that need a specific fit should be called out with the coating allowance in mind.
Tell us the finish before machining. We adjust the bore and thread dimensions so the coated part still fits.
A STEP or IGES model plus a 2D drawing showing tolerances, datums and finish callouts. If the drawing is not ready, send the model and note the critical fits.
Quotation and free DFM analysis come back within 12 hours. Uploads stay confidential, and an NDA is available on request.
Yes. There is no minimum order quantity, so one shell or one full set is fine. The same program carries into a 10,000+ part run if the design moves to production.
Production can start within 24 hours of drawing approval, and parts ship in 3–5 days.
We agree on which faces stay visible before machining. Those get finer stepover, bead blasting or brushing, and masking during finishing.
Laser marking is available with a minimum character height of 1.5 mm. Send the logo or part number as vector art.
Every part is inspected before shipment: raw material check, in-process monitoring, and a final dimensional check. Reports are available on request.
If something is out, we tell you before it ships and quote the rework or remachining path. That is cheaper than finding it at assembly.
Upload your STEP files and drawing. You get a quotation, DFM feedback and a machining plan, then parts in 3–5 days.
12-hour quote100% inspectionNo minimum order quantityNDA 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.
CNC Metals 13 grades
CNC Plastics 10 grades
Machines & processes 12 options
Surface & post-processing 10 options
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