Optimizing Production for Custom Hydraulic Valve Blocks
How Allied Metal helped a European equipment manufacturer reduce unit costs by 30% through DFM analysis and smart tooling strategies.
- Heavy Machinery
- Aluminum 6061-T6
- 15 Days (Batch)
- -30% Cost
The Challenge
Our client, a mid-sized European brand specializing in hydraulic systems, designed a new generation valve block. The functionality was excellent, but the manufacturing economics were failing.
High Cost: The complex internal channels required 5-axis machining in a single setup, driving machine hourly rates too high.
Capacity Issues: Their local suppliers couldn’t handle the volume, and previous overseas attempts resulted in leakage issues due to poor tolerance control.
Our DFM Solution
Upon receiving the CAD files, Allied Metal’s engineering team didn’t just quote the part; we analyzed the manufacturability. We identified that 90% of the features could be done on a cheaper 3-axis or 4-axis machine.
Monolithic block requiring continuous 5-axis movement to reach undercut areas.
$$$ High Machining Cost
Proposed a split-design modification and custom fixture that allowed for 4-axis machining without compromising pressure rating.
√ 30% Cost Saving
Production & Results
Once the design was approved, we moved to rapid production. We utilized our **Okuma 4-Axis Horizontal Machining Centers** for the main body to ensure perpendicularity and flatness.
Quality Assurance Data
Critical Dimension Tolerance: ±0.005mm (Pass)
Surface Roughness (Internal): Ra 0.8 (Pass)
Leakage Test: 100% Passed @ 300 Bar
Project Specs
Process
CNC Milling (4-Axis), Boring
Material
Aluminium 6061-T6
Surface Finish
Hard Anodizing (Type III) Black
Volume
500 units / batch
“Allied Metal’s engineering team saved us thousands of Euros on the first run alone. The parts fit perfectly.”
John D.
Product Manager, EuroHydraulics
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