A customer asked us to manufacture a very demanding component with 0.1 mm wall thickness and internal features requiring a smooth surface. The initial destructive analysis identified tool chatter marks with in the deep, hidden recesses of the part that would not be acceptable. Through careful frequency tuning of the cutting tool by relocating certain setscrews, we removed the internal harmonics and created a chatter-free toolpath. Creative problem solving combined with deep experience and a dedication to customer satisfaction is one of Little Lakes hallmarks.

Our customer requires a highly accurate surface across the entire tool – time and time again.  The surface features are first milled into copper and then carefully EDM burnt into the tool’s active surface. Our dedicated 3D optical micro CMM provides the reassurance and proof that what we deliver on our promises.

Sometimes bigger is better, especially when milling features with tight radii into hardened materials like D2 or DC53. On our big Makino horizontal mill, the spindle and the parts holding are super stable, eliminating any vibration that could mar the quality of the final tool. Our customer’s flow forming tool is the product of this perfect alignment of equipment and know-how.