Working with our client in the telecommunications field, McAlpin Industries fabricated and assembled this featured mechanical assembly for a network server application. We began by designing and building all the necessary fixtures and tooling needed for manufacturing, relying on wire EDM machining processes. Metal fabrication involved a combination of countersinking, press brake forming, laser cutting, shearing, thread tapping, and deburring, followed by TIG welding and PEM staking. We used two different PEM nut sizes: M3 x 5 x 1.02 mm and 6-32 x .060 in. All assembly was done manually, followed by riveting.

To ensure the quality of our work, we used an Amada CNC laser cutter during manufacturing. The final assembly measured 15.200 in. long, and we held a close, .003 in. tolerance, as well as a .040 in. flatness tolerance. We finished the assembly with zinc plating. After ensuring all design and manufacturing standards had been met, as outlined in our client-supplied print, we delivered the mechanical assembly to our client.