Custom Machining and
Design Support Services

We provide engineering support and build custom machinery for companies that require unique solutions. Our experienced team has built parts and machines for various industries, including aerospace, medical, food and beverage, and more. We work closely with our customers to understand their specific needs and create customized solutions that meet or exceed their expectations. Our team handles all phases of the project, including:

• Base or frame welding and fabricating
• Component part machining
• Raw materials and commercially available component procurement
• All secondary processes, such as plating and anodizing
• Painting and specialty finishing (e.g., CARC coatings)
• Complete mechanical assembly
• Pneumatic or hydraulic system plumbing
• Main control cabinet, including PLC wiring and operator stations, wiring
• Debugging, testing, and checkout
• Final skidding, crating, and shipping

Advantages of Custom Machine Building

Compared to off-the-shelf equipment, custom machinery offers significant advantages, such as:

• Form and function that perfectly complement your facility’s existing layout
• Capabilities aligned to your individual production requirements
• Maximum ROI

Industries That Utilize Custom Machine Building

Some of the industries we serve with our custom machine building services include:

• Aerospace
• Electronics
• Energy
• Food processing
• Medical

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Our experience building custom machines provides us with the knowledge and skills needed to offer automated control panel wiring services. We can create custom panel wiring and control systems for machines of any size, from small production line equipment to large-scale industrial machinery. Our team works with you to design a custom control panel that meets your specific needs and integrates seamlessly with your existing equipment.

Common Components

Each control panel is unique to the machine it is designed for. However, some common components that we often install include:

• Programmable logic controllers (PLCs): automate control processes
• Central processing units (CPUs): control PLCs
• Input/Output (I/O) cards: manage the transmission and receipt of analog/digital signals
• PLC wiring: connect I/O cards to PLC terminals
• Alarms: monitor systems and alerts employees to potential problems
• Reset/emergency stop buttons: allow for system reset or shut-off in an emergency
• Power supply: power the assembly

Advantages of Automated Control Panel Wiring

There are several advantages to investing in a custom panel wiring solution for equipment, such as:

• Faster response time
• Smaller footprint
• Lower risk of leakage
• Better space efficiency

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Milling is a machining process that utilizes rotary cutting tools to shape a workpiece. During 3-axis milling operations, the workpiece can only be cut on the X, Y, and Z axes. However, 5-axis milling allows work to be performed on two additional axes from the following options: the A-axis (rotates around the X-axis), the B-axis (rotates around the Y-axis), or the C-axis (rotates around the Z-axis). The combination of the added axes depends on the type of milling machine used.

5-axis machines offer many benefits, including increased precision and accuracy, reduced setup time, and the ability to create complex shapes. At Astro Machine Works, we have state-of-the-art 5-axis milling machines and highly skilled machinists to ensure that your parts are manufactured with the highest quality.

Advantages of 5-Axis Machining & Milling

Compared to other manufacturing processes, 5-axis milling has many advantages when used to create parts and products, such as:

• Quicker production of complex shapes
• Higher quality surface finishes on components
• Easier setup requirements

Industries That Utilize 5-Axis Machining & Milling Services

Some of the industries that regularly rely on 5-axis machining for the manufacture of their components include:

• Aerospace
• Automotive
• Energy
• Industrial
• Medical

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Computer numerical control (CNC) machining refers to machining operations that use computer-guided equipment to remove material from a workpiece to achieve the desired shape and size. At Astro Machine Works, we specialize in providing high-quality CNC precision machining services for various industries and applications. Our state-of-the-art equipment and experienced machinists allow us to produce complex parts with tight tolerances.

Advantages of CNC Precision Machining

CNC machining offers many advantages over conventional manufacturing processes, including:

• Tighter tolerances
• Shorter lead times
• Reduced labor costs

Capabilities at Astro Machine Works

Our team maintains the capabilities for CNC milling and CNC turning operations. While CNC milling uses a rotating cutting tool to cut a stationary workpiece, CNC turning uses stationary cutting tools to cut a rotating workpiece. Our CNC milling capabilities include 3-axis or 5-axis milling for prototype or fully functional components. Our CNC turning capabilities include live tooling for multitasking machining, making us a one-stop shop for all your precision machining needs.

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Wire electrical discharge machining (EDM) is an advanced machining technique that shapes or finishes a workpiece using electrical sparks generated by a wire electrode. It is commonly utilized to cut plates or form tools from hard materials unsuitable for other machining processes. Astro Machine Works has a team of skilled machinists who specialize in Wire EDM machining to produce high-precision and complex parts for various industries.

Advantages of Wire EDM

Some of the key advantages of using Wire EDM to manufacture parts and products include:

• Lower risk of workpiece damage
• Better surface and edge finish
• Faster turnaround times

Wire EDM Machining Capabilities at Astro Machine Works

We maintain a range of in-house capabilities, allowing us to complete various EDM projects. Additionally, our continual investment in new equipment and employees enables us to stay ahead of the competition and provide customers with quality solutions. Our Wire EDM machining capabilities include:

• High precision cutting with tolerances up to +/-0.0001”
• Thick plate cutting up to 12” thick
• Advanced solid modeling software for complex shapes

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Contract manufacturing refers to a relationship between a company and a third-party manufacturer in which the contracting organization outsources some or all of its manufacturing operations to the contracted organization. This arrangement allows the contracting organization to focus on other aspects of their business while relying on the expertise and capabilities of the contracted manufacturer. Astro Machine Works offers various contract manufacturing services to meet our customers’ needs.

Advantages of Contract Manufacturing

A contract manufacturing partnership benefits the contracting company in numerous ways, including:

• Improving scalability
• Lowering production costs
• Freeing up resources

Industries That Utilize Contract Manufacturing

Many industries leverage contract manufacturers to produce their parts and products, including, but not limited to, the following:

• Aerospace
• Automotive
• Electronics
• Food and beverage
• Medical
• Pharmaceutical
• Robotics and automation

Capabilities at Astro Machine Works

Our team can conduct over 20,000 contract manufacturing hours per month. We can accommodate the following:

• All metals and alloys as well as select non-metallic materials
• Custom automation machinery up to 50 feet in length and 75,000 pounds in weight
• Various structural shapes, including angles, beams, channels, plates, and tubes
• Turning for parts up to 40 inches in diameter and 160 inches in length
• Milling for parts up to 118 inches x 236 inches x 47 inches
• Surface grinding for parts up to 16 inches x 28 inches
• Wire EDM for parts up to 23.62 inches x 15.75 inches x 19.69 inches
• Waterjet, laser, plasma, flame, and saw cutting

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In addition to making new custom machines, we maintain the capabilities to repair, rebuild, and refurbish existing machinery. Investing in a custom rebuild or refurbishment offers the same efficiency enhancements as buying new equipment at a comparatively lower cost. We also offer ongoing maintenance and support to prolong the life of your machines. Our machine repair services include:

• Mechanical and electrical troubleshooting
• Control panel wiring and programming
• Preventative maintenance plans
• Motor, gearbox, and hydraulic system repair and replacement

Machine Rebuilding Process

A typical machine rebuilding project begins with a thorough inspection of the machine. The inspection results accurately assess how much work will be required to rebuild the machine and how long it will take to complete the work. If the customer approves the recommended solution, our experienced team will disassemble the machine and replace or rebuild any worn or damaged components. We then reassemble the machine, test it, and ensure everything functions correctly before delivering it to the customer.

Capabilities at Astro Machine Works

We can repair a variety of machines, including:

• All types of heavy machinery
• Pneumatic and hydraulic cylinders
• Brakes
• Lathes
• Grinders
• Hydraulic presses

We can also handle CNC retrofitting tasks.

Industries Served

We proudly provide our repair, rebuild, and refurbishment services to small, medium, and Fortune 500 companies across a range of industries, including:

• Aerospace
• Energy
• Food processing
• General manufacturing

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Companies using older equipment sometimes find that a critical component is no longer available. Reverse engineering enables them to create the missing piece rather than replace the entire machine. Our reverse engineering services begin with an evaluation of the existing component. We determine its purpose, how it was manufactured, and what materials were used to make it. Afterward, we create a detailed CAD model of the component using our advanced solid modeling software.

Reverse Engineering Application Examples

Reverse engineering can be used for various purposes, including:

• Re-engineer a faulty component
• Developing formal part specifications
• Modifying and reproducing existing parts

Capabilities at Astro Machine Works

The team at Astro Machine Works has over 30 years of experience providing high-precision machine part solutions. By utilizing advanced computer-aided reverse engineering technology, we can reverse engineer parts and products quickly and cost-effectively from a sample of the worn or broken piece. We can also make necessary design changes or improve the part’s functionality. Our team has experience reverse engineering a wide range of parts, including:

• Shafts and rollers
• Gears and gearboxes
• Transmission housings

Industries That Utilize Reverse Engineering

Industries we serve with our reverse engineering capabilities include:

• Electronics
• Food processing
• General manufacturing
• Telecommunications

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We use our fabrication and welding services in many of our more comprehensive projects (e.g., custom machine builds and contract manufacturing jobs). Fabrication refers to any industrial process that transforms raw material into a finished component, while welding specifically refers to processes that use heat and pressure to join metal components.

Capabilities at Astro Machine Works

Our capabilities include:

• Fabrication: casting, cutting, machining
• Welding: MIG welding, TIG welding, stick welding, orbital welding
• Finishing & testing: passivation, dye penetrant testing, specialty cleaning
• Materials: aluminum, carbon steel, stainless steel, titanium, specialty alloys
• Shapes: angles, beams, channels, tubes

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