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CNC Machining of Aluminum Expansion Coupler for the Electrical Hardware Industry

Custom Aluminum Expansion CouplerFairchild Auto-Mated Parts, Inc. CNC machines 2,500 to 5,000 expansion couplers annually for a client from the electrical hardware industry. Used within a rain-proof conduit connector, these couplers are made from 6061 aluminum, and measure 6.505" in length and 1.54" in outside diameter, with a 1.528" x 1.025" material extrusion.

Before manufacturing these couplers, Fairchild technical engineers design the connectors' dimensions to minimize machining and material costs. Once the client approves this design, we then begin producing these components on an ongoing basis.

Holding tolerances as close as ± .001", we use a combination of our 3-axis CNC lathe and CNC-retrofitted screw machine to manufacture each coupler. Customer part numbers and brand logos are also roll-engraved onto the exterior surface of the couplers, and we perform in-process testing and final inspections to ensure all units meet client expectations for quality. Once completed, the expansion couplers are shipped to various North American locations.

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Aluminum Expansion Coupler Project Highlights

Product Description This aluminum expansion coupler is used within a rain proof conduit connector
Capabilities Applied/Processes
Design
  • Designed Connector Dimensions to Minimize Machining & Material Costs
CNC Machining
Roll Engraving
Equipment Used to Manufacture Part
3-Axis CNC Lathe CNC-Retrofitted Screw Machine
Overall Part Dimensions
Material: 1.528" x 1.025" Extrusion
Length: 6.505"		 O.D.: Ø1.54"
Tightest Tolerances ±.001"
Materials Used 6061 Aluminum
Max Material Finish 32 Ra
Features Roll Engraved Customer Part Number and Brand Logo
Inspection Performed In Process & Final Inspection
Tooling Cost $595
Estimated Part Weight 7.24 oz.
Industry for Use Commercial Electrical Hardware Distribution
Packaging Individual Cells
Volume Manufactured 2,500 to 5,000 Per Year
Turn Around Time 8 Weeks
Delivery Location North America
Standards Met Customer supplied specifications
Product Name Expansion Coupler

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