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🇩🇪 German EV Client: High-Precision Aluminum Parts CNC Machining Project

Project Background

In early 2023, we received an inquiry from a client in the German automotive industry. The company is a developer of custom components for new energy vehicles (NEVs), serving major OEMs across Europe.

They discovered our company through our official website and were looking for a Chinese supplier with strong 5-axis CNC machining capabilities, the ability to respond quickly to prototyping needs, and full compliance with EU quality standards.

The aluminum parts in this project were intended for the powertrain structural module of a newly developed electric vehicle. The components featured complex geometries and extremely tight tolerances, placing high demands on machining stability, accuracy, and consistency.

Client Requirements

The client provided 3D drawings and technical specifications for three aluminum alloy components, with the following key requirements:

  • Material
  • Processing Method
  • Tolerance
  • Surface Treatment
  • Sample Lead Time
  • Quantity

AL7075 aluminum
±0.01mm tolerance for critical dimensions
Clear anodizing (Black color)
5-axis simultaneous CNC machining recommended
Within 7 working days
5 pcs per part for sampling; estimated monthly volume of 50–100 pcs for future batches

Key Technical Challenges

  • The components featured complex geometries, including multiple angled surfaces, deep grooves, and fine through-holes, which required advanced 5-axis programming and optimized toolpath strategies.
  • The customer demanded both high surface flatness and cosmetic appearance, with no visible tool marks allowed.
  • As the client is based in Germany, efficient and clear communication was critical to avoid delays in the engineering process.
  • The tight lead time (7 working days including surface treatment) placed additional pressure on production planning and coordination.

Challenges & Solutions

Our Solution

Upon receiving the inquiry, we immediately organized a project review meeting involving the project manager, CAM programmer, and quality control supervisor to assess feasibility. Key optimization measures included:

We raised several clarification questions regarding unspecified areas in the client’s drawings to ensure mutual understanding. The client responded quickly, allowing for efficient and smooth communication

Our CAM engineers used PowerMILL to plan 5-axis toolpaths and conducted full simulations to avoid tool collisions and overcutting. For complex geometries, small-diameter tools were applied in segmented passes to ensure dimensional accuracy

We prioritized the project on our in-house 5-axis machining centers, arranging two shifts per day to accelerate turnaround time

We pre-booked slots with our local anodizing partner and inserted this project into an early production batch to ensure on-time surface finishing

We conducted 100% inspection of critical dimensions using CMM (Coordinate Measuring Machine) and included a detailed inspection report with the shipment

As a result, the parts were fully machined and anodized by Day 6, inspected and packed on Day 7, and then promptly shipped to the client

jnady
jnadyThe client responded within 48 hours of receiving the samples
"Very impressive machining quality. All key tolerances are within our limits. The parts look clean and professionally done."

Future Collaboration

After the successful sample verification, the client began placing small-batch production orders the following month.
We’ve now been working together for over 9 months, supporting multiple development projects. The client is currently evaluating us for tier-2 supplier qualification in their volume production program.

The client especially recognized our strengths in

  • Rapid prototyping response time
  • Precision control
  • Efficient communication(with technically sound English replies from our engineers)
  • Flexible scheduling & low-volume batch production capabilities

Project Summary

This project highlights our capabilities in high-precision CNC machining, fast turnaround for prototypes, and seamless communication with international clients.

We not only met the client’s stringent technical standards, but also demonstrated flexibility, speed, and consistency—laying a solid foundation for long-term collaboration.

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JoeVin

Joe Vin is the Operations Director at Alec Model, a CNC machining and 3D printing manufacturer in China. With full in-house production and years of hands-on experience, he helps global clients solve real-world manufacturing challenges — from prototyping to production.

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