An integrated flange connector combines multiple inlet/outlet ports, mounting bosses, and sealing surfaces into one monolithic component. Our CNC machining process handles angular port drilling, intersecting bores, undercut seal grooves, and non‑standard bolt circles that would be impossible with cast or welded construction. We produce prototypes from 1 piece and scale to volume lots without sacrificing geometric repeatability.
Why Choose Integrated Machining?
|
Feature |
Traditional Welded Assembly |
Our One-Piece Machined Solution |
|
Leak paths |
Multiple weld joints & gaskets |
Zero welds; single billet |
|
Port alignment |
Tolerance stack-up risk |
±0.03 mm port-to-port in one setup |
|
Weight |
Heavy flanges + fittings |
20–30 % lighter, compact envelope |
|
Fatigue life |
Weld heat-affected zone |
Uniform grain structure |
Technical Specifications
- Max envelope: 600 × 400 × 300 mm
- Port positional tolerance: ±0.03 mm
- Seal surface flatness: 0.02 mm over 100 mm
- Surface finish: Ra 1.6–3.2 μm standard; Ra 0.8 μm for precision seals
- Thread standards: UNF, BSPP, NPT, SAE O‑ring boss (custom threads available)
- Pressure rating: Up to 5,000 psi (depending on material and wall thickness)
Standards & Certifications
Our quality system is built on internationally recognized standards:
|
ISO 9001:2015 |
Quality management system for consistent process control |
|
IATF 16949:2016 |
Automotive sector quality requirements, including PPAP and SPC |
|
Material compliance: |
RoHS and REACH compliant upon request |
|
Dimensional reporting: |
ASME Y14.5 GD&T standards applied to all customer drawings |
Every shipment includes a material certificate (MTC) and dimensional inspection report traceable to the heat number.
Machining Process Details
We machine integrated flange connectors through a controlled, documented workflow:
- Billet prep: Solid bar or forged blank cut to rough size, with material heat number logged
- 5-axis roughing: High-speed adaptive clearing removes bulk material while maintaining low tool load
- Precision finishing: Seal faces and port bores are finish-machined in a single fixture to preserve geometric relationships
- Cross-hole deburring: High-pressure coolant and specialized tools remove all burrs from intersecting bores, critical for hydraulic cleanliness
- In-process probing: On-machine touch probes verify critical dimensions before the part leaves the fixture, preventing out-of-tolerance parts from advancing
Inspection & Quality Report
Quality is documented, not assumed:
|
CMM with rotary probe |
Measures 3D port centers, flange flatness, and angular relationships against the original CAD model |
|
Bore gaging & profilometer |
Confirms seal surface roughness (Ra) and diameter tolerances |
|
Pressure testing |
Hydrostatic or pneumatic leak testing available on request |
|
Inspection report |
Serialized report includes measured values, tolerance bands, pass/fail status, and inspector signature |
|
Traceability |
Report number linked to material heat number, machine operator, and production date |
Typical Materials
- Stainless Steel: 304, 316, 316L, corrosive fluid and marine environments
- Alloy Steel: 42CrMo, 40Cr, high-pressure hydraulic blocks
- Aluminum: 6061-T6, 7075-T6, weight-sensitive automotive manifolds
- Carbon Steel: 45#, Q235, general industrial with protective coating
Typical Applications
- Automotive: Turbocharger oil‑feed and coolant manifolds with integrated mounting flanges
- Hydraulics: Compact valve blocks and pump manifolds requiring multiple SAE or BSPP ports
- Industrial Power: Generator cooling and fuel distribution headers
Request a Drawing Quotation
Submit your 2D/3D drawings, operating conditions, and estimated volume. Our engineers will review your Integrated Flange Connector Machining requirements and return a detailed DFM proposal, material recommendation, and competitive quote within 48 hours. Trial samples welcome.
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