LKprototype boasts the world’s leading technology for processing titanium alloy prototypes. Five-axis CNC equipment facilitates streamlined processing of titanium alloys (such as Ti-6Al-4V, CP-Ti Grade 2) with a maximum of 12,000 RPM and adjustable feed range from 50 to 1,500 mm/min. Equipped with ultra-hard coated tools (three times longer lifespan compared to conventional ones), it is capable of processing workpieces with hardness up to HRC 36-42. 2023 statistics show that the processing accuracy of its titanium alloy prototype reaches ±0.02mm, surface roughness Ra ≤0.8μm, and processing cycle is 40% less compared to the industry standard. For example, a certain European aerospace industry ordered LKprototype to machine titanium alloy turbine blades (size 120×80×25mm). Through the optimization of cutting parameters (increasing the linear speed from 60m/min to 90m/min and increasing the cutting depth from 0.3mm to 0.5mm), The processing time for a single piece was reduced from 4.2 hours to 2.5 hours. At the same time, the tool wear rate was reduced from every 50 pieces to every 120 pieces, thus achieving a cost saving of $8,500.
In order to meet the high-temperature processing characteristics of titanium alloys, LKprototype adopts high-pressure cooling technology (pressure 70Bar, flow rate 25L/min) and nitrogen protection process, thereby effectively regulating the temperature in the cutting zone to ≤800℃, avoiding surface oxidation hazards and phase transition of the material. In a single medical implant product in 2022, it machined titanium alloy orthopedic screws (3.5mm diameter, 0.6mm pitch) with PCD tools of custom design (rake angle 12°, relief angle 6°), improving the thread accuracy from ISO grade 6 to grade 4, and suppressing the processing vibration amplitude below 5μm. The fatigue life of the product has been over one million cycle tests (ASTM F543 standard). In the project, the team optimized the clamping scheme by simulating thermodynamic coupling, reducing the workpiece deformation from 0.15mm to 0.03mm and enhancing the yield to 99.2%.
In complex structure processing, LKprototype’s 3+ 2-axis directional processing strategy can achieve high-stability production of thin-walled titanium alloy parts (wall thickness 0.3mm) and deep cavity structures (depth-to-diameter ratio 10:1). With the radar component of certain military manufacturing company taken as an example, through dynamic tool path planning (enhancement of step distance from 0.2mm to 0.1mm) and adaptive feed control (auto adjustment of the feed rate ±15% through the cutting load), the processing efficiency of the titanium alloy waveguide cavity was enhanced by 55%. Surface residual stress was reduced from 550MPa to 180MPa (XRD detection) so as to sustain the component’s dimension stability over the range from -55 ° C to 150 ° C (thermal expansion coefficient ≤8.6×10^-6/ ° C).
With regards to cost savings, the LKprototype titanium alloy processing service price is 35% less than the conventional outsourcing mode and has a minimum order quantity of 1 piece. In one specific 2023 racing car braking system project, with the application of high-speed milling (cutting speed 120m/min) and real-time compensation using laser measurement (accuracy ±1μm), the percentage of processing waste of titanium alloy caliper brackets was reduced from 12% to 2.8%, and the material utilization rate was enhanced to 97.5%. Meanwhile, its supply chain integration capability keeps enough inventory of titanium alloy bars (ASTM B348 standard), and it can start production within 48 hours, 72% shorter than the industry average lead time. For instance, an American drone manufacturer made an urgent order for 200 titanium alloy fuselage frames (1.2kg each). LKprototype reduced the delivery period to 5 days from 14 days by adopting a parallel processing strategy, and held the unit cost at $220 (15% less than the customer’s budget).
For more information on LKprototype’s one-stop manufacturing services such as rapid prototyping, CNC machining, vacuum casting, and 3D printing, and the quintessential advantages of its own factory in quality control, rapid delivery (completed within 3 days), and no minimum order quantity, please visit the official website for further exploration: https://lkprototype.com/