Motorola Rapid Prototyping Services produces a large number of CNC machined Engineering Prototypes for all levels of functional product evaluation. Machining is our original core competency, and we have continuously invested in new hardware, software, systems and training to maintain world-class capabilities, focused on speed and accuracy.

We machine Engineering Prototypes from many plastics, metals and composite materials. Customer requests typically range from one to 100 parts, and may focus on a single, key component, or include all of the mechanical parts in a product. Customers use our machined parts for everything from thermal and RF testing to evaluating acoustical and environmental performance.

Parts machined from glass-filled polycarbonate (click image to enlarge)

Effective use of Engineering Prototypes helps product design teams refine and stabilize the functional details of their parts and assemblies, reducing the chance that later design changes will interrupt and add cost to the tooling cycle.

Our capabilities include vertical and horizontal milling centers, wire and die-sinking EDM, and a full complement of supporting processes including custom milling and turning, grinding, tumbling, heat treating, media blasting, and welding.

Our experience with milling plastics, both neat (unfilled) and as composites is extensive. In some cases, when specialty materials are not available as machining stock, we have the capability of molding small and medium-sized billets from injection molding resins, and using these as machining stock. We have also developed a custom modular fixturing system that makes these molded stock materials convenient to load and unload with automatic positioning.

3-Axis Milling

Machines by Makino, Roku, Chiron, Fanuc and Tree

Maximum Machining Envelope (XYZ) = 27" x 16" x 10" (Fanuc)

Maximum Tool Capacity = 40 (Makino V33)

Fanuc Controllers on all Machines

Vacuum Fixtures, Clamp Fixtures, Tape, Vise, and custom workholding

Small Machined Lightpipe (click image to enlarge)

4-Axis Milling

Kitamura MyCenter Horizontal

Maximum Machining Envelope (XYZ) = 20" x 20" x 20"

Maximum Tool Capacity = 40

Fanuc Controller

Rotary pallet changer with programmable C axis (static or dynamic)

Chick Tombstone Pallet System

Custom machinable 'soft jaws' for part fixturing

Customer Data Requirements

3-D CAD data in portable format (iges, stl, step, vdi) or Pro/E

Detailed Color, Materials, and Finishes documentation for all surfaces

All required graphics including logos, screen displays, labels

CNC Programming

Primary Platform - Mastercam X3

Toolpath verification - Vericut

Toolpath optimization - Optipath

CNC Machined Aluminum Chassis 6 sides machined in 2 operations

We use a combination of software tools to ensure high as-machined dimensional accuracy, good surface quality, and efficient high speed machining. The majority of our part machining is done using Mastercam. We maintain an extensive software definitions library of cutting tools and substrate materials, which our programmers access to ensure we machine with optimal conditions.

We have also implemented process verification software to identify risk areas in machining, and ensure a high success rate. This software simulates the entire machine environment, including table, spindle, workholding, tool checking, and cutting tool library. Most recently, we have also implemented a cutting path optimizer, which maintains constant material removal rates, making sure there is a constant loading on the cutting tool. This provides us with a significant time savings

Fine detail CNC milling in Aluminum (click image to enlarge)

We can combine our in-house machining operations with value-added processes from our suppliers, including plating, conversion coatings, painting or powder coating. In addition to part machining, we produce parts for assembly and test fixtures to support product qualification and pilot builds. In some cases we also perform small quantity product assembly, or tool or fixture assembly.