Project Overview
Key Challenges
This project involved several machining and production challenges. The parts are slender tapered shafts, meaning long and thin components that are highly prone to vibration during turning. At the same time, the customer required a high-quality surface finish, while standard machining typically results in visible tool marks that require additional grinding. The order was also split into three different sizes within a small batch of 55 pcs, increasing setup complexity and reducing efficiency. In addition, conventional lathes lack sufficient stability and machining length for this type of work. All of these challenges were compounded by a strict 20-day deadline, including both production and international logistics under DDP terms.
Technical Analysis
The core challenge of this project was not the geometric complexity, but process optimization. The focus was on reducing vibration during turning, improving surface finish to eliminate tool marks, increasing machining accuracy, shortening the production cycle, and optimizing cost efficiency for small-batch CNC machining. Achieving all these factors simultaneously required both process innovation and equipment adaptation.
Our Capabilities
Precimach provided strong support for this project through its specialized capabilities in shaft machining. The company operates a dedicated shaft machining workshop equipped with advanced CNC lathes capable of handling up to 14 meters in length, as well as precision grinding machines up to 8 meters. With over 10 years of experience in precision shaft manufacturing and a global customer base of more than 2,000 clients, Precimach has extensive expertise in handling complex and customized projects. The machining range covers lengths from 0.2m to 14m and diameters starting from 10mm, with full support for custom CNC machining services.
Solution & Process Optimization
After reviewing the drawings, it was clear that standard steady rests were insufficient for maintaining stability when machining tapered slender shafts. To solve this, Precimach developed a custom hydraulic telescopic follow rest designed to stabilize the workpiece during turning, significantly reduce vibration, and improve machining consistency. Rapid prototyping was immediately initiated to validate machining stability, surface finish quality, and dimensional accuracy. The prototype confirmed that the solution was effective, achieving a smooth surface without visible tool marks.
To meet the tight delivery timeline, production was launched based on the validated process while further optimization continued in parallel. The initial limitation of the first-generation follow rest was that it required two-step machining with re-clamping, which affected efficiency. To address this, Precimach upgraded the system to a CNC-synchronized hydraulic follow rest that enables automatic position adjustment during machining. This improvement allowed a one-pass turning process, resulting in higher precision and reduced machining time. The upgraded solution significantly enhanced production efficiency, surface consistency, and cost control for future orders.
Results
The project was successfully completed with delivery finished 7 days ahead of schedule. All parts fully met dimensional and surface quality requirements, and real-time updates were provided to the customer throughout production and air freight shipping. The order was delivered to the USA under DDP terms within the 20-day deadline.
Customer Impact
The customer highly appreciated Precimach’s fast response, strong engineering capability, and reliable delivery performance. Although this was a low-margin trial order, it successfully built trust and created a strong foundation for future bulk orders. At the same time, the investment in new tooling and process optimization strengthened Precimach’s competitiveness in tapered shaft machining and improved scalability for high-volume production.
Conclusion
This project demonstrates Precimach’s ability to deliver high-precision custom CNC machining under tight deadlines while continuously improving processes and investing in advanced solutions. With a focus on quality, speed, and total cost efficiency, Precimach remains a reliable partner for global customers in both prototype development and mass production.
