Solving Complex Geometry Manufacturing: Dawang's Approach To Impossible Parts

Struggling with complex part geometries? Dawang Precision specializes in manufacturing components with internal channels, thin walls, and organic shapes others can't produce. Learn our approach.

When Aerospace Innovations Ltd approached us with their new satellite guidance component, their lead engineer told us, "Three other manufacturers said this can't be made." The part featured internal cooling channels that followed complex curved paths, thin walls measuring just 0.3mm thick, and required materials that were notoriously difficult to machine.

This wasn't our first "impossible" part, and it wouldn't be the last. Complex geometry manufacturing represents one of the most challenging aspects of precision engineering. At Dawang Precision, we've developed a systematic approach to tackling these challenges that combines advanced technology with deep material knowledge.

The part in question required five specific capabilities that most machine shops lack:

• Ability to machine internal channels with changing diameters

• Maintenance of ±0.01mm tolerance on thin walls

• Processing of titanium 6Al-4V, known for being difficult to machine

• Surface finish better than Ra 0.4µm in internal passages

• Documentation of every manufacturing step for aerospace compliance

Our solution involved a four-stage process that has become our standard for complex geometries:

Stage 1: Collaborative Design Analysis

• We assembled a team including:

• Two senior machinists with 25+ years experience

• Our materials science specialist

• Quality assurance lead

• The client's design engineer

Through three virtual sessions, we identified several manufacturability issues. The original design had sharp internal corners that were impossible to machine. We suggested radius modifications that maintained function while enabling production. We also recommended adjusting wall thickness consistency to improve structural integrity.

Stage 2: Hybrid Manufacturing Approach

• We employed a combination of technologies:

• 5-axis machining for the primary structure

• Micro-EDM for the intricate internal features

• Electrical polishing for internal surface improvement

• CT scanning for internal dimensional verification

The magic happened in how we sequenced these operations. By machining the part 80% complete, then using EDM for the most complex internal features, and finishing with precision machining of critical surfaces, we achieved results that single-process manufacturing couldn't match.

Stage 3: Custom Tooling Solutions

• Standard tooling wouldn't work for this project. We designed and manufactured:

• Specialized extended-reach tools with vibration dampin

• Custom fixtures that supported the part at 17 different points

• Cooling systems that maintained temperature within ±1°C during machining

Stage 4: Advanced Metrology

• We faced the challenge of verifying internal dimensions without destructive testing. Our solution involved:

• Industrial CT scanning to create 3D models of internal structures

• Comparison of scan data to original CAD models

• Custom-developed software algorithms to analyze wall thickness variations

• Comprehensive reporting for aerospace compliance

The results exceeded expectations:

• Parts met all dimensional requirements with 100% compliance

• Surface finishes measured Ra 0.3µm, better than specification

• Delivery occurred two weeks ahead of schedule

• Cost came in 15% below the client's budget

What makes our approach different isn't just the technology - it's the mindset. We've learned that complex geometry manufacturing requires:

• Early collaboration with design teams

• Willingness to combine different manufacturing processes

• Investment in specialized tooling and fixturing

• Advanced measurement capabilities

• Thorough documentation practices

Today, that satellite component flies on six different spacecraft, and Aerospace Innovations has become one of our most valued partners. They've since brought us seven more "impossible" projects, each pushing the boundaries of what manufacturing can achieve.