🇺🇸 Ohio-Based Industrial Automation Client | Custom CNC Machining of Aluminum Mounting Brackets for Robotic Gripper Assembly

Project Background

In May 2025, we received a repeat inquiry from a long-term client based in Ohio, USA—an automation integrator specializing in high-speed packaging lines for the food and personal care sectors.

The client was developing a new end-of-line robotic gripper designed for lightweight SKU handling. The design called for a custom-machined aluminum bracket, intended to interface between the gripper’s pneumatic housing and the modular mounting arm. They needed tight tolerances on bore spacing and a clean anodized surface to withstand frequent tool changes.

Advantages of Using a Custom CNC Machined Aluminum Bracket

As a trusted partner familiar with their documentation and packaging expectations, we were brought in to quickly prototype and deliver a pilot batch.

Client Requirements

Specification

Material
Part Size
Features
Tolerance
Surface
Volume
Timeline
Docs

Description

6061-T6 aluminum (ASTM B221, extrusion stock)
160 mm × 95 mm × 16 mm
Two through-holes + M6 tapped holes + lateral counterbores
±0.02 mm on mounting hole distances, ±0.05 mm overall
Clear anodized (Type II, Class 1), no dye
6 prototypes, with expected batches of 100–150 per run
8 working days from PO to FedEx shipment
CMM inspection sheet, anodizing cert, packaging photos, traceable label set

Key Technical Challenges

1️⃣ Parallel Flatness for Face Mounting

The bracket must sit flush against the gripper body and toolchanger interface. Even minor warping after machining or anodizing could cause stress on housing seals.

2️⃣ Controlled Counterbore Depth

The counterbores needed to clear washer heads with <0.1 mm tolerance. Poor tool control would result in floating washers or over-sunk screw heads.

3️⃣ Fine Surface Handling for Repeat Assembly

Repeated tool mounting/unmounting demanded a smooth but unpolished surface—too rough and the bracket would wear quickly, too soft and it would pick up marks.

Challenges & Solutions

Pre-Machining

Used U.S.-sourced 6061-T6 extrusion plates (material cert included)

Pre-milled the stock to stabilize flatness before roughing

Used tight-grip aluminum fixtures for minimal stress

Step 1: CNC Process

Machined with HSK toolholders on 3-axis center

Final passes at 8,000 RPM with 2-flute finishing mills

Counterbores controlled with Z-probe calibration and post-process gauge check

Step 2:Surface Finishing & QA

Partner anodizer applied clear Type II finish with consistent tone

Anodizing thickness tested at 10–12 μm per customer spec

Full CMM report generated in English with ballooned drawing for each feature

Step 3: Labeling & Packing

Parts laser-marked on reverse face with unique batch code

Packed in foam-lined kraft trays with individual part separators

Shipping box included dual-language labels, QA checksheet, and FedEx ID photo

“We trust you guys because we don’t have to explain things twice. You got the mounting faces dead flat and the finish looks better than local anodizers.”

Future Collaboration

Following the successful delivery and integration of the aluminum bracket, our client has expressed interest in expanding cooperation beyond prototyping and low-volume production. We are now in discussions to support them with additional components for their robotic arm series, including custom end-effectors and mounting plates.

They also plan to introduce a new automation module later this year, for which we’ve been invited to participate in the DFM (Design for Manufacturing) phase early on. With our experience in CNC machining for precision robotics and our reliable turnaround times, we’re well-positioned to grow with their evolving product line.

This collaboration continues to reinforce our role as a trusted manufacturing partner for high-precision automation components in the U.S. market.

The client especially recognized our strengths in

The 6-piece prototype was delivered in 7 working days, ahead of schedule. The gripper modules passed toolchanger assembly testing on first fit. We have since quoted a batch run of 120 pieces and are preparing to supply additional sensor brackets in the same platform.

Project Summary

This project shows how we support long-term partners by:

Delivering tight-tolerance aluminum parts on short lead times

Maintaining clean anodized finishes for field-facing components

Providing complete documentation, labeling, and export-ready packaging

Whether it’s a one-off prototype or scaled delivery, we speak the same language as your shop floor—and deliver parts that fit, mount, and hold up over time.

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.