Featured Project
End-to-End Engineering & Manufacturing Solutions
Solid Machine has the engineering know-how, depth of experience, specialized software, and facilities to manufacture complex turbomachinery flowpath components up to Ø650mm (Ø26”) for aerospace, automotive, defense, energy, oil & gas, and industrial applications.
One project that uniquely highlights our engineering and manufacturing capabilities is when a client in the oil & natural gas sector asked us to provide an aftermarket field replacement for an Ø18” compressor impeller in duplex stainless steel.
The project was a success and the engineering and manufacturing solutions that we performed to serve our client included the following:
STEP
1
Reverse Engineering
Utilized a wide range of metrology equipment along with a team that has years of experience with rotating bladed turbomachinery hardware to reverse engineer the 2-D features and 3-D flowpath.
STEP
2
3-D Modeling
Converted the XYZ 3-D data points into a model defining all edge forms (arcs, ellipses, fillets), smoothing out imperfections, and validating the CAD model back to the scanned object.
STEP
3
Drafting
Produced a detailed multi-page set of blueprints documenting all of the reverse engineered data and features.
Partnered with our client to discuss and document the final tolerances, finishes, and specifications.
STEP
4
Programming
Created custom CNC lathe programs in MasterCAM® and 5-axis milling programs in Concepts NREC MAX-PAC™.
STEP
5
Machine Simulation
Created NC data and carried out a simulation to check for machine interference and other potential issues using CAMplete Truepath to ensure that actual production proceeds reliably and smoothly.
STEP
6
Material Procurement
Expedited the delivery of a large forging in a less common grade of material and validated the certs for conformance to the customer requirements and specs.
STEP
7
Manufacturing
Performed all CNC turning (including lab seals) and 5-axis blade milling in conformance with the customer requirements and specs.
STEP
8
Subcontracted Services
Subcontracted secondary services to outside vendors in accordance with customer requirements and specs (such as electroless nickel plating including masking of the bore and other features per the photo on the right).
STEP
9
Final Inspection & Shipment
Provided a 100% 2-D inspection and validation of the 3-D flowpath along with all required certs and specs.
Packaged the part in a custom wooden crate.
Solid Machine | 61 Airport Dr.- Unit 1 | Rochester, New Hampshire 03867
Phone: (603) 332-5511 | E-mail: info@solidmachinenh.com
