01
The edge break call comes too late
A sharp corner on a mating face chips during deburring, or anodize builds up on a 0.2 mm chamfer and the part will not seat. One line on the drawing decides whether the assembly passes or gets reworked.
Machining Guides
Machinist Resources for Everyday Shop Decisions
Material pairings, edge breaks, thread locking and tolerance calls, written by machinists for engineers who have to release the drawing. Use these notes to pick a process before you cut metal.
±0.005 mmRa 0.2–0.8 μm127 CNC machinesNo MOQ
15 yearsMachining since 2011
127High-precision CNC machines
3Wholly-owned plants
99.99%Qualification rate
Shop Floor Reality
Where These Notes Save You Money
Four problems that show up after the drawing is released, not before.
02
The fillet that costs a second setup
An internal corner drawn at R0.4 mm needs a small cutter, slow feed and a long cycle. Relax it to R2 mm and the same pocket runs on a standard tool. The radius is a cost decision, not a cosmetic one.
03
Bolts that loosen in the field
Vibration works a plain joint apart even at the correct torque. Preload drops, the clamp load falls, and the failure looks like a broken fastener when the real cause is thread locking.
04
The tolerance nobody can measure
A ±0.01 mm call on a feature with no datum reference cannot be inspected, so it becomes a dispute. Datums and a clear measuring method settle it before the first chip.
How We Work
Notes From a Shop That Runs the Parts
Two calls decide most jobs: which process, and which edge.
Process Selection
Pick the process before the material
Titanium against stainless is not a density contest. Ti-6Al-4V has a low density and a low thermal conductivity, so heat stays in the cut and tool edges wear fast. Stainless 316 machines with a gummier chip and work-hardens if the feed stops. Weight matters, but the real driver is stiffness, corrosion and the number of parts.
On a bracket that sees salt spray, 316L wins on corrosion and loses on cost. On a part that must be light and stiff, TC4 wins and costs more in cycle time. We quote both when the choice is close.
- 1Titanium TC4Light, strong, slow to cut, poor heat path
- 2Stainless 316LCorrosion resistant, work-hardens if feed stalls
- 36061-T6Cheap, fast, good for housings and fixtures
Edge and Joint Detail
Chamfer, fillet, or neither
A chamfer removes a sharp edge and gives a lead-in for assembly. A fillet spreads stress over a radius and is the right call where a crack would start. The cost sits in the detail: a chamfer runs with a standard tool in one pass, while a tight internal fillet forces a small cutter and a slower feed.
For bolts that must stay tight, the locking method matters more than the torque figure. Nylon patch, thread locker, a serrated flange or a Nord-Lock washer each suit a different service condition. Pick by how often the joint is opened, not by habit.
- 1ChamferDeburr and lead-in, one standard pass
- 2FilletFatigue relief, needs the right cutter radius
- 3LockingMatch the method to service and rework frequency
Selection Table
Which Detail Fits the Job
Use the service condition, not the drawing convention.
| Situation | Better Call | Why |
|---|---|---|
| Mating face, painted part | Chamfer 0.3–0.5 mm | Coating builds on edges, blocks seating |
| Fatigue-loaded shaft shoulder | Fillet R2 mm or larger | Spreads stress, delays crack start |
| Joint opened for service | Nylon patch or thread locker | Removable, repeatable preload |
| Permanent high-vibration joint | Serrated flange or locking washer | Resists loosening without adhesive |
| Weight-critical bracket | TC4 titanium | Low density, high stiffness |
| Salt-spray housing | 316L stainless | Chloride resistance, no plating needed |
What We Run
Services Behind These Guides
One shop for the prototype and the production run.
01
5 Axis CNC Machining
16 simultaneous 5-axis centers for contoured parts and one-setup work.
02
CNC Milling & Turning
Mills and 16 mill-turn centers for prismatic and round parts, Ø400 mm rotary table.
03
Rapid Prototyping
From one prototype upward, with DFM feedback inside 12 hours.
04
Sheet Metal Fabrication
Brackets, panels and enclosures that pair with machined parts.
05
Part Surface Finishing
Anodize, plating, powder coat, bead blast and laser marking to 1.5 mm characters.
06
Custom 3D Printing
Plastic prototypes to check fit before the metal parts are cut.
Capability
Range and Inspection
Numbers you can check against your drawing.
| Item | Range | Note |
|---|---|---|
| Maximum part size | 4,000 mm | 4,000 × 400 × 150 mm travel |
| Tolerance held | ±0.005 mm | ±0.0002 in, verified in process |
| Fine finish | Ra 0.2–0.8 μm | Bead blast or polish where needed |
| As-machined finish | Ra 1.6–3.2 μm | Default for non-critical faces |
| Materials | Al, stainless, steel, Ti, Cu | Including 7075, 17-4PH, TC4, Inconel |
| Inspection | 100% before shipment | Reports available on request |
Why GreatLight
What the Shop Brings
Data first, adjectives later.
15Y
Machining since 2011
Fifteen years of production work across three plants in Dongguan and Singapore.
127
CNC machines
16 five-axis, 12 four-axis, 27 three-axis and 16 mill-turn centers under one roof.
±0.005
Tolerance
Held on production parts, checked in process and again before shipment.
12 h
Quote turnaround
Quotation with free DFM analysis, then production can start within 24 hours.
0
Minimum order quantity
From one prototype to runs above 10,000 parts, same process control.
4
Certifications
ISO 9001, IATF 16949, ISO 13485 and ISO 27001 cover quality and files.
7,600 m²Manufacturing space
150Technicians on staff
3–5 daysTypical shipping window
<2%Historical late-delivery rate
Industry Fit
What Each Sector Requires, and What We Deliver
Aerospace brackets
Thin walls and tight faces need stable setups and documented inspection.
- ±0.005 mm
- 100% inspection
Automotive and EV housings
Repeatability across batches matters more than a single good part.
- IATF 16949
- 10,000+ runs
Medical instrument parts
Clean edges, no burrs and traceable material from a controlled process.
- ISO 13485
- Ra 0.2–0.8 μm
Robotics and automation
Mounting faces and bores must line up first time, across many small lots.
- No MOQ
- 3–5 day ship
FAQs
Questions From the Drawing Board
When should I choose titanium over stainless for a bracket?
Choose titanium when weight and stiffness drive the design and corrosion is handled by the alloy itself. TC4 (Ti-6Al-4V) gives a high strength-to-weight ratio but cuts slowly because heat stays at the edge.
Choose 316L when chloride resistance and cost matter more than mass. It machines faster and needs no plating, but it work-hardens if the feed stops.
Chamfer or fillet on an internal corner?
A chamfer is for deburring, lead-in and coating relief. It runs in one pass with a standard tool.
A fillet is for fatigue. If a crack would start at that corner, the radius does the work, but a tight R0.4 mm call forces a small cutter and a longer cycle. R2 mm is usually free.
How do I stop bolts from loosening?
Match the method to how often the joint is opened. Nylon patch or medium thread locker suits serviceable joints. A serrated flange or locking washer suits permanent high-vibration joints.
The torque figure alone will not hold a joint that loses preload every cycle.
What tolerance can you actually hold on a production part?
We hold ±0.005 mm (±0.0002 in) and verify it in process, then again before shipment.
If a feature cannot be measured with a clear datum, the call becomes a dispute. Add datums and a measuring method on the drawing.
Which surface finish should I specify?
Ra 1.6–3.2 μm is the as-machined default and is fine for non-critical faces. Ra 0.8–1.6 μm covers sealing and sliding fits. Ra 0.2–0.8 μm is for fine work and adds cycle time.
Specify the finish only where it does a job.
Can you run one part and then scale up?
Yes. There is no minimum order quantity, and the same process control applies from one prototype to runs above 10,000 parts.
Quotation with a free DFM analysis comes back within 12 hours; production can start within 24 hours.
How are my files handled?
Uploads are secure and confidential, and we can sign an NDA on request.
ISO 27001:2022 covers our information handling, so drawings and models stay inside the controlled system.
What do you need to quote a job?
A 3D model or a dimensioned drawing, the material, the finish and the quantity. Note any critical tolerances and the inspection you expect.
Send those and the DFM feedback comes with the price, so you can fix cost drivers before cutting metal.
Put These Notes to Work on Your Part
Send a model or drawing and get a quotation with free DFM analysis within 12 hours.
12-hour quote100% inspectionNo MOQ
