Electrical Discharge Machining of an Aluminum Flexure Base

Our team at EMF, Inc. manufactured this flexure base for a customer in the communications industry who is based at the Kennedy Space Center in Florida. The base is constructed of aluminum 7075-T651, which is an extremely high strength aluminum alloy. We routinely work with exotic and expensive materials and have the necessary quality controls in place to prevent the scrapping of costly parts. This small flexure base measures approximately 2.5" in length, 0.625" in width, and 0.3125" in height. The base was machined via electrical discharge machining (EDM). EDM is an ideal process for machining precision single piece or low-volume parts that are sensitive to the heat distortion caused by traditional machining techniques.

For this part, true position tolerances were held to as tight as ±0.005" and surface profiles were held to ±0.002". We have full inspection capabilities, including CMM and profilometer measurement equipment to ensure that all dimensional tolerances are met. The machined base was given a chemical conversion coating in accordance with MIL-C-5541 specifications. The finished part underwent functionality and proof load testing before delivery to the customer. For additional details regarding this custom electrical discharge machining project, see the table below, or contact us directly.

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Electrical Discharge Machining of an Aluminum Flexure BaseElectrical Discharge Machining of an Aluminum Flexure Base
Electrical Discharge Machining of an Aluminum Flexure Base
Electrical Discharge Machining Services of an Aluminum Flexure BaseElectrical Discharge Machining Services of an Aluminum Flexure Base
Electrical Discharge Machining Services of an Aluminum Flexure Base

Manufacturing of an Aluminum Flexure Base Project Highlights

Product Name
Flexure Base
Project Description
Custom manufacturing and electrical discharge machining of a flexure base for a customer in the aerospace industry.
Capabilities/Processes Applied
Primary:
  • Cutting
  • Coating
  • Testing
Equipment Used to Manufacture this Flexure Base
Electrical Discharge Machining (EDM)
Overall Part Dimensions
Length: ~2.5"
Width: ~5/8"
Height: ~5/16"
Tightest Tolerances
±0.005" for Position
±0.002" for Surface Profile
Material Used
Aluminum 7075-T651
Material Finish
Chemical Conversion Coating MIL-C-5541
In Process Testing & Inspection Performed
Functionality Testing
Proof Load Testing
Industry for Use
Communications
Delivery Location
Kennedy Space Center, FL
Standards Met
ASME Y14.5, Customer standards

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