When a Tier One heavy truck engine manufacturer approached Aerostar with a demanding task – a large-scale production run of fuel manifolds – we faced a two-fold challenge. Not only did the production involve a part with complex geometries and deep fluid passageways, but the uncompromising quality requirements called for the manifolds to be entirely free from finishing burrs and leaks. The critical cleanliness factor added another layer of complexity, necessitating a highly specialized approach.
Traditional deburring methods were rendered impractical due to the part’s intricate design. This prompted Aerostar to employ innovative techniques and exhibit our ability to provide custom solutions tailored to our clients’ needs. After the initial machining of the metal, we turned to a thermal deburring process. This sophisticated technique allowed us to effectively remove any impurities or burrs from the manifolds, even within the deepest recesses and cavities.
To further ensure the absolute cleanliness of the parts, each piece was subjected to a rigorous millipore test. This highly sensitive test effectively measures and analyzes any particulate contamination, offering a precise cleanliness verification process. Additionally, to validate the absence of leaks, an air-testing procedure was conducted. This meticulous, two-tier testing approach allowed us to confidently guarantee the impeccable quality of the manifolds.
Delivering to the client’s expectations, Aerostar successfully managed the on-time shipment of parts, adhering to the stipulated schedule. The customer’s response was overwhelmingly positive, particularly appreciating our innovative approach, efficient process, and uncompromising adherence to quality standards. This project underscores Aerostar Manufacturing’s commitment to overcoming complex challenges and delivering high-quality, efficient solutions, tailored to meet and exceed our customers’ exacting requirements.