Case Study

Aerospace Case Study 13 / 15

Spacecraft Structural Part Machining Case Study

Communication SatelliteEarth Observation SatelliteSpace TelescopeSpace ProbeSpace Station Module

spacecraft structural part machining case studyaerospace cnc machining5 axis aerospace machining

Case Overview

Core project data for this machining case.

Industry Aerospace & Space

Product Spacecraft Structural Parts

Material Aluminum 6061-T6 / 7075 / Ti-6Al-4V

Process CNC Milling + Precision Drilling + Inspection

Machine Model HYR VMC850 / VMC1060 / VMC1165

Tolerance +/-0.005 mm

Surface Finish Ra0.4

Application Satellites / Spacecraft / Space Stations / Deep Space Missions

Customer Background

Production context behind the case.

This project comes from a Aerospace & Space manufacturing requirement for Satellites / Spacecraft / Space Stations / Deep Space Missions. The buyer needed stable machining quality, repeatable inspection results and a machine configuration suitable for real production rather than a one-time sample.

Machine Selection

Why this machine configuration was selected.

HYR-CNC selected the machine plan around part size, material, tolerance, surface finish, tool capacity and expected production volume. The recommended setup focuses on rigidity, spindle stability, fixture access, tool change efficiency and inspection control.

Problem

Machining problem to solve

Spacecraft components require:Low Weight+High Strength+Dimensional Stability+Precision AssemblyBecause they combine:Lightweight designThin-wall geometryPrecision assembly requirements

Solution

HYR-CNC machining plan

The customer manufactures:Satellite structuresPayload support systemsSpace electronics housingsPrecision aerospace assembliesMaterials:

Machine Used

Recommended machine configuration

Machine: HYR CNC machining center selected according to aerospace material, part size and tolerance

Process: Rough machining, semi-finishing, 5-axis finishing and inspection based on the document content

Accuracy Control: Rigid fixturing, thermal stability, deformation control and CMM inspection

Cost Method: Published with existing website assets first to keep implementation cost low

Process

Timeline from raw material to inspection.

01 Material preparation

02 Rough machining

03 Semi-finishing

04 5-axis finishing

05 Inspection

Full Case Article

Machining background, difficulty and solution logic.

Quick Facts

Item

Details

Industry Aerospace & Space Product Spacecraft Structural Parts Materials Aluminum 6061-T6 / 7075 / Ti-6Al-4V Process CNC Milling + Precision Drilling + Inspection Machine HYR VMC850 / VMC1060 / VMC1165 Tolerance +/-0.005 mm Surface Finish Ra0.4 Application Satellites / Spacecraft / Space Stations / Deep Space Missions

Introduction

Every spacecraft relies on a structural system.

Communication SatelliteEarth Observation SatelliteSpace TelescopeSpace ProbeSpace Station Module

all require precision structural components.

Structural components must survive every stage.

Whether it is: These structures provide: Mechanical support Equipment mounting Load transfer Thermal stability Dimensional accuracy During launch: Launch VibrationAcoustic LoadAccelerationOrbit Deployment For this reason: Spacecraft Structures=Lightweight+High Stiffness+Extreme Reliability

What Are Spacecraft Structural Parts?

Spacecraft structural components include:

Primary Structures

Responsible for: Load CarryingSystem Integration Examples: Main frames Structural panels Equipment decks Support beams

Secondary Structures

Responsible for: Subsystem Installation Examples: Brackets Mounting plates Sensor supports Electronics frames

Payload Structures

Responsible for: Scientific InstrumentsOptical SystemsCommunication Equipment Examples: Optical benches Payload frames Antenna supports

Satellite Housing

Function: Protect ElectronicsSupport Payloads Related Article: -> Satellite Housing Machining Case Study

Payload Support Structure

Function: Instrument InstallationAlignment Maintenance Requirements: High rigidity Thermal stability

Optical Bench

Function: Optical Alignment Requirements: Micron-Level Stability Applications: Telescopes Imaging satellites Deep space missions

Antenna Mount

Function: Communication System Support Requirements: Lightweight Dimensional accuracy

Equipment Deck

Function: Subsystem Installation Platform Applications: Power systems Communication modules Flight computers

Customer Background

HYR CNC developed a complete spacecraft structure machining solution.

The customer manufactures: Satellite structures Payload support systems Space electronics housings Precision aerospace assemblies Materials: 6061-T67075 AluminumTi-6Al-4V Main challenges: Weight reduction Thin-wall machining Flatness control Hole position accuracy Thermal stability

Why Spacecraft Structures Are Difficult To Machine

Spacecraft components require: Low Weight+High Strength+Dimensional Stability+Precision Assembly

Challenge 1

Launch costs remain extremely high.

Engineers remove material wherever possible.

Aggressive Lightweighting Therefore: Every Gram Matters Resulting structures often contain: Large pockets Thin ribs Honeycomb features Complex cavities

Challenge 2

Thin-Wall Machining Typical wall thickness: 1 mm5 mm Problems: Distortion Chatter Dimensional instability

Challenge 3

Precision Interface Requirements Structural parts often include: Mounting SurfacesAlignment FeaturesPositioning Holes Requirements: Flatness Parallelism Position accuracy

Challenge 4

Thermal cycling requires stable materials and precision machining.

Thermal Stability Space environment: -150 degreesC+120 degreesC

Aluminum 6061-T6

Advantages: LightweightGood MachinabilityCorrosion Resistance Applications: Satellite structures Electronic housings

Aluminum 7075

Advantages: Higher StrengthExcellent Weight Ratio Applications: Structural supports High-load interfaces

Ti-6Al-4V

Advantages: High StrengthLow DensityLong-Term Reliability Applications: Critical support structures Spacecraft interfaces

HYR VMC850

Suitable for: Small aerospace parts Precision brackets Payload components

HYR VMC1060

Suitable for: Satellite structures Equipment frames Housing components

HYR VMC1165

Suitable for: Large spacecraft structures Precision support systems

Step 1

Material Preparation Use: Aluminum plate Titanium plate Forged blanks

Step 2

Rough Machining Remove: 60-80% Material Create: Weight reduction pockets Structural ribs

Step 3

Stress Relief Reduce: Residual StressDistortion

Step 4

Semi-Finishing Machine: Support structures Interfaces Mounting surfaces

Step 5

Finish Machining Requirement: Tolerance +/-0.005 mmRa0.4

Step 6

Deburring Remove: Burrs Sharp edges

Step 7

Surface Treatment Possible options: Anodizing Chemical conversion coating Protective finishing

Step 8

Inspection Verify: Flatness Hole positions Structural dimensions

Flatness Inspection

Requirement: ≤0.02 mm

Hole Position Inspection

Requirement: +/-0.01 mm

Surface Finish Inspection

Requirement: Ra0.4

CMM Inspection

Verify: Complete geometry Structural interfaces Assembly compatibility

Results

Item

After implementing HYR machining solutions: Before After Flatness 0.05 mm 0.02 mm Position Accuracy +/-0.03 mm +/-0.01 mm Cycle Time 100% -25% Scrap Rate 1.1% 0.1% Structural Weight Baseline -10%

HYR VMC850

Small precision structures

HYR VMC1060

Satellite and spacecraft modules

HYR VMC1165

Large aerospace structural components

What Is Aerospace CNC Machining?

Satellite Housing Machining Case Study Rocket Engine Component Machining Case Study Titanium Machining Case Study Thin Wall Aerospace Part Machining Case Study

What are spacecraft structural parts?

They are load-bearing and support components used to integrate, protect and position spacecraft systems and payloads.

Why are spacecraft structures difficult to machine?

Because they combine: Lightweight design Thin-wall geometry Precision assembly requirements Thermal stability demands

What materials are commonly used?

6061-T6, 7075 aluminum and Ti-6Al-4V titanium.

Why is weight reduction important?

Reducing launch mass improves mission efficiency and lowers launch costs.

What tolerance is typical?

or better.

Most spacecraft structures require: +/-0.005 mm

Conclusion

Spacecraft structural components form the foundation of modern space systems.

Their lightweight designs, precision interfaces and demanding environmental requirements require advanced CNC machining solutions.

With extensive aerospace machining experience and stable manufacturing capability, HYR CNC provides reliable and efficient solutions for spacecraft structural component production.

Result

Before and after machining improvement.

Item	Before	After
Result 1	Before optimization	After implementing HYR machining solutions:
Result 2	Before optimization	Flatness
Result 3	Before optimization	0.05 mm

FAQ

Common buyer questions for this case.

What is this aerospace article about?

This page covers spacecraft structural parts requirements, machining difficulty, process planning and machine selection.

Which machines are recommended?

HYR VMC, HMC and 5-axis machining centers are selected according to material, size, tolerance and contour complexity.

Can HYR-CNC support similar aerospace parts?

Yes. Send drawings, material, tolerance and production volume for a suitable machining proposal.

Download brochures and technical references.

Use the download center to review machine catalogs, brochure files and supporting documents before requesting a quotation.

Open Downloads

Similar Case Studies

Need a similar CNC machining solution?

Send your drawing, material, tolerance, surface finish and production volume. HYR-CNC will recommend the right machine configuration and machining proposal.

Start Machine Selection

Spacecraft Structural Part Machining Case Study

Core project data for this machining case.

Production context behind the case.

Why this machine configuration was selected.

Machining problem to solve

HYR-CNC machining plan

Recommended machine configuration

Timeline from raw material to inspection.

Machining background, difficulty and solution logic.

Quick Facts

Introduction

What Are Spacecraft Structural Parts?

Primary Structures

Secondary Structures

Payload Structures

Satellite Housing

Payload Support Structure

Optical Bench

Antenna Mount

Equipment Deck

Customer Background

Why Spacecraft Structures Are Difficult To Machine

Challenge 1

Challenge 2

Challenge 3

Challenge 4

Aluminum 6061-T6

Aluminum 7075

Ti-6Al-4V

HYR VMC850

HYR VMC1060

HYR VMC1165

Step 1

Step 2

Step 3

Step 4

Step 5

Step 6

Step 7

Step 8

Flatness Inspection

Hole Position Inspection

Surface Finish Inspection

CMM Inspection

Results

HYR VMC850

HYR VMC1060

HYR VMC1165

Related Articles

What are spacecraft structural parts?

Why are spacecraft structures difficult to machine?

What materials are commonly used?

Why is weight reduction important?

What tolerance is typical?

Conclusion

Before and after machining improvement.

Common buyer questions for this case.

What is this aerospace article about?

Which machines are recommended?

Can HYR-CNC support similar aerospace parts?

Download brochures and technical references.

More Aerospace machining proof.

Aircraft Structural Part Machining Case Study

Wing Rib Machining Case Study

Bulkhead Machining Case Study

Need a similar CNC machining solution?

Related Products

Related Industries

Knowledge