{"id":15308,"date":"2026-08-04T09:00:00","date_gmt":"2026-08-04T07:00:00","guid":{"rendered":"https:\/\/tps-elektronik.com\/?post_type=case_studies&#038;p=15308"},"modified":"2026-07-07T07:57:07","modified_gmt":"2026-07-07T05:57:07","slug":"how-to-reduce-assembly-time-with-tps-multi-axis-aluminum-cnc-machining-for-integrated-brackets-and-complex-geometries","status":"publish","type":"case_studies","link":"https:\/\/tps-elektronik.com\/en\/case-studies\/how-to-reduce-assembly-time-with-tps-multi-axis-aluminum-cnc-machining-for-integrated-brackets-and-complex-geometries\/","title":{"rendered":"How to Reduce Assembly Time with TPS Multi-Axis Aluminum CNC Machining for Integrated Brackets and Complex Geometries?"},"content":{"rendered":"<article class=\"blog-post\" lang=\"en\"><header>\n<p>System integrators and OEMs rarely fail because they lack a functional design. They lose time\u2014and budget\u2014when the mechanical assembly of dozens of small, individual brackets, fasteners, and mounting plates becomes a hidden bottleneck on the production floor. A leading manufacturer of industrial packaging machinery faced exactly this challenge with their new high\u2011speed cartoning module. The initial prototype required over 15 labor hours per unit just to assemble the frame and sensor mounting structure from a kit of 17 separate aluminum parts. The complexity of the assembly not only slowed throughput but also introduced potential points of misalignment and failure.<br \/>TPS Elektronik\u2019s <strong>multi-axis aluminum CNC machining service<\/strong> brought in to solve this problem. By applying a design\u2011for\u2011manufacturing review and leveraging 5\u2011axis CNC technology, TPS successfully consolidated the 17\u2011part assembly into a single, monolithic, precision\u2011machined aluminum bracket. This case study details the collaboration and the manufacturing techniques that dramatically reduced assembly time. Which improved quality, and accelerated time\u2011to\u2011market.<\/p>\n<p><a class=\"cta-primary\" href=\"https:\/\/tps-elektronik.com\/en\/services\/ems\/pcb-assembly\/\">Request a multi\u2011axis CNC machining consultation \u2192<\/a><\/p>\n<\/header><nav class=\"toc\" aria-label=\"Table of contents\">\n<h2 id=\"toc-en\">Table of contents<\/h2>\n<ol>\n<li><a href=\"#en-challenge\">The assembly time challenge<\/a><\/li>\n<li><a href=\"#en-solution\">The TPS multi\u2011axis CNC integration solution<\/a>\n<ol>\n<li><a href=\"#en-design\">Design for integration: from 17 parts to one<\/a><\/li>\n<li><a href=\"#en-precision\">Precision 5\u2011axis machining and material selection<\/a><\/li>\n<\/ol>\n<\/li>\n<li><a href=\"#en-results\">Measurable results: reduced assembly time and cost<\/a><\/li>\n<li><a href=\"#en-rfq\">RFQ checklist for integrated aluminum brackets<\/a><\/li>\n<li><a href=\"#en-faq\">FAQ<\/a><\/li>\n<\/ol>\n<\/nav>\n<section id=\"en-challenge\">\n<h2>1. The assembly time challenge<\/h2>\n<p>The packaging machine\u2019s main sensor and actuator mounting frame originally designed as a bolted assembly of 17 individual components: laser\u2011cut brackets, threaded spacers, and adapter plates. Each part required manual alignment and tightening with calibrated torque wrenches. The documented assembly procedure, including quality checks, took over 16 hours per machine. Which creating a significant bottleneck during a critical ramp\u2011up phase. The design\u2019s reliance on multiple fasteners also introduced the risk of loosening due to machine vibration, threatening long\u2011term reliability. The procurement team urgently needed a partner who could deliver a <strong>custom aluminum CNC machining service<\/strong> to consolidate these parts into a single, precision\u2011machined component without sacrificing functionality.<\/p>\n<\/section>\n<section id=\"en-solution\">\n<h2>2. The TPS multi\u2011axis CNC integration solution<\/h2>\n<p>TPS proposed a complete redesign of the structure, leveraging its extensive experience in precision machining for integrated mechatronic systems. The solution was based on 5\u2011axis CNC machining of a solid billet of 6061\u2011T6 aluminum, a technique that allows complex geometries with undercuts and angled holes to produced in a single setup. This approach is a key capability detailed in our overview of <a href=\"https:\/\/tps-elektronik.com\/en\/types-of-milling-machine\/\">types of milling machines<\/a> and the discussion on <a href=\"https:\/\/tps-elektronik.com\/en\/top-cnc-milling-machine-options\/\">top CNC milling machine options<\/a>.<\/p>\n<p><img decoding=\"async\" class=\"alignnone size-full wp-image-15360\" src=\"https:\/\/tps-elektronik.com\/wp-content\/uploads\/2026\/07\/5\u2011Axis-CNC-Machining-Integrated-Aluminum-Bracket-Complex-Geometry-\u2013-TPS-Elektronik-1.jpg\" alt=\"5\u2011Axis CNC Machining Integrated Aluminum Bracket Complex Geometry \u2013 TPS Elektronik 5\u2011Achs\u2011CNC\u2011Bearbeitung integrierte Aluminiumhalterung komplexe Geometrie \u2013 TPS Elektronik\" width=\"1920\" height=\"1079\" \/><\/p>\n<h3 id=\"en-design\">2.1 Design for integration: from 17 parts to one<\/h3>\n<p>The design process began with a detailed DFM review. TPS engineers worked closely with the customer to ensure that all critical mounting points, sensor targets, and cable routing channels from the original 17\u2011part assembly were accurately reproduced in a single, monolithic design. Internal 3D\u2011printed prototypes of the new part produced to validate the form and fit before committing to aluminum. The final design not only eliminated all 102 fasteners but also reduced the overall weight by 15\u202f% and improved the structural stiffness, as described in our related service on <a href=\"https:\/\/tps-elektronik.com\/en\/ems-cnc-milling-precision-machining-prototype-to-production\/\">precision machining from prototype to production<\/a>.<\/p>\n<h3 id=\"en-precision\">2.2 Precision 5\u2011axis machining and material selection<\/h3>\n<p>The monolithic bracket machined from a single billet of aircraft\u2011grade 6061\u2011T6 aluminum, chosen for its excellent strength\u2011to\u2011weight ratio, corrosion resistance, and machinability. A 5\u2011axis CNC machining center used to access all five exposed faces of the part in a single setup. This eliminated the tolerance stack\u2011up that occurs when re\u2011fixturing a part for multiple 3\u2011axis operations. Which ensuring that every mounting hole, bearing seat, and sensor alignment feature was perfectly oriented. The entire machining cycle completed in a fraction of the time previously required to assemble the multi\u2011part structure. The high\u2011speed machining strategies and tooling employed further detailed in our overview of <a href=\"https:\/\/tps-elektronik.com\/en\/ems-cnc-milling-electronics-fast-rfq-dfm\/\">EMS CNC milling for electronics: DFM and fixture strategy<\/a>.<\/p>\n<\/section>\n<section id=\"en-results\">\n<h2>3. Measurable results: reduced assembly time and cost<\/h2>\n<p>The switch to the monolithic TPS\u2011machined bracket delivered immediate, quantifiable benefits. The total assembly time for the frame slashed from over 16 hours to just 2 hours, representing an 87\u202f% reduction in direct labor per unit. This allowed the customer to double their daily production output without hiring additional assembly technicians. Furthermore, the elimination of 102 fasteners and the associated manual alignment steps reduced the direct material cost per unit by 18\u202f%. The CMM inspection report provided with each bracket guaranteed its dimensional accuracy, eliminating the need for post\u2011assembly adjustment and rework. This success story perfectly illustrates the value of integrating precision CNC machining with a holistic understanding of the final assembly process.<\/p>\n<p><img decoding=\"async\" class=\"alignnone size-full wp-image-14594\" src=\"https:\/\/tps-elektronik.com\/wp-content\/uploads\/2026\/06\/cnc-steel-plate-cutting.jpg\" alt=\"cnc steel plate cutting\" width=\"1920\" height=\"1280\" srcset=\"https:\/\/tps-elektronik.com\/wp-content\/uploads\/2026\/06\/cnc-steel-plate-cutting.jpg 1920w, https:\/\/tps-elektronik.com\/wp-content\/uploads\/2026\/06\/cnc-steel-plate-cutting-600x400.jpg 600w\" sizes=\"(max-width: 1920px) 100vw, 1920px\" \/><\/p>\n<\/section>\n<section id=\"en-rfq\">\n<h2>4. RFQ checklist for integrated aluminum brackets<\/h2>\n<ul>\n<li><strong>CAD models<\/strong>: 3D STEP files of the desired monolithic design, or the original assembly for TPS to propose an integrated DFM solution.<\/li>\n<li><strong>Material specification<\/strong>: Alloy preference (e.g., 6061\u2011T6), surface finish (anodizing, chem\u2011film), and any required material certifications.<\/li>\n<li><strong>Functional requirements<\/strong>: Tapped hole sizes, critical flatness requirements, and any press\u2011fit inserts.<\/li>\n<li><strong>Quantities and schedule<\/strong>: Prototype, pilot, and series production volumes.<\/li>\n<li><strong>Inspection requirements<\/strong>: CMM reporting and PPAP documentation if applicable.<\/li>\n<\/ul>\n<p><a class=\"cta-primary\" href=\"https:\/\/tps-elektronik.com\/en\/services\/ems\/pcb-assembly\/\">Submit your integrated bracket RFQ \u2192<\/a><\/p>\n<\/section>\n<section id=\"en-faq\">\n<h2>5. FAQ<\/h2>\n<p><strong>What is the main advantage of using a monolithic machined bracket over an assembly?<\/strong><br \/>It eliminates tolerance stack\u2011up, drastically reduces assembly labor, and improves structural rigidity by removing bolted joints. Which resulting in a more reliable and cost\u2011effective final product.<\/p>\n<p><strong>How many parts can typically be consolidated into a single CNC bracket?<\/strong><br \/>There is no fixed limit, but assemblies containing anywhere from a few parts to over 20 individual components can often be consolidated into a single, optimized monolith.<\/p>\n<p><strong>Can TPS handle the necessary post\u2011machining surface finishing?<\/strong><br \/>Yes, TPS provides a full range of surface finishes, including anodizing (clear, black, or colored) and chromate conversion coating, all managed as an integrated service.<\/p>\n<p><strong>Where can I learn more about TPS\u2019s broader machining capabilities?<\/strong><br \/>Visit our overview on <a href=\"https:\/\/tps-elektronik.com\/en\/precision-cnc-machining-high-accuracy\/\">precision CNC machining for high accuracy<\/a> or the dedicated <a href=\"https:\/\/tps-elektronik.com\/en\/services\/ems\/pcb-assembly\/\">PCB assembly service page<\/a>.<\/p>\n<\/section>\n<footer style=\"background: #2d5797; padding: 30px; border-radius: 14px; margin-top: 40px;\">\n<p style=\"color: #ffffff; font-size: 16px; line-height: 1.6; margin: 0;\"><strong>Ready to turn your complex assembly into a single, precision\u2011machined component?<\/strong><br \/>Contact TPS Elektronik for a multi\u2011axis CNC machining service that reduces assembly time and improves product quality.<br \/><a style=\"color: #ffffff; font-weight: 600; text-decoration: underline; display: block; margin-top: 10px;\" href=\"https:\/\/tps-elektronik.com\/en\/services\/ems\/pcb-assembly\/\">Request your multi\u2011axis CNC machining consultation \u2192<\/a><\/p>\n<\/footer><\/article>\n\n<style id=\"wpforms-css-vars-4659-block-d9106af6-9c76-45a5-bb9c-6caa717a84ea\">\n\t\t\t\t#wpforms-4659.wpforms-block-d9106af6-9c76-45a5-bb9c-6caa717a84ea {\n\t\t\t\t--wpforms-field-size-input-height: 43px;\n--wpforms-field-size-input-spacing: 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They lose time\u2014and budget\u2014when the mechanical assembly of dozens of small, individual brackets, fasteners, and mounting plates becomes a hidden bottleneck on the production floor. A leading manufacturer of industrial packaging machinery faced exactly this challenge with their new high\u2011speed cartoning module. The\u2026 <a href=\"https:\/\/tps-elektronik.com\/en\/case-studies\/how-to-reduce-assembly-time-with-tps-multi-axis-aluminum-cnc-machining-for-integrated-brackets-and-complex-geometries\/\">Read More &raquo;<\/a><\/p>\n","protected":false},"author":9,"featured_media":14594,"template":"","class_list":["post-15308","case_studies","type-case_studies","status-publish","has-post-thumbnail","hentry"],"acf":[],"yoast_head":"<!-- This site is optimized with the Yoast SEO plugin v28.1 - https:\/\/yoast.com\/product\/yoast-seo-wordpress\/ -->\n<title>How to Reduce Assembly Time with TPS Multi-Axis Aluminum CNC Machining for Integrated Brackets and Complex Geometries? - TPS<\/title>\n<meta name=\"description\" content=\"TPS multi-axis aluminum CNC machining service consolidates parts into single monolithic brackets, drastically reducing assembly time and costs for complex geometries.\" \/>\n<meta name=\"robots\" content=\"index, follow, max-snippet:-1, max-image-preview:large, max-video-preview:-1\" \/>\n<link rel=\"canonical\" href=\"https:\/\/tps-elektronik.com\/en\/case-studies\/how-to-reduce-assembly-time-with-tps-multi-axis-aluminum-cnc-machining-for-integrated-brackets-and-complex-geometries\/\" \/>\n<meta property=\"og:locale\" content=\"en_US\" \/>\n<meta property=\"og:type\" content=\"article\" \/>\n<meta property=\"og:title\" content=\"How to Reduce Assembly Time with TPS Multi-Axis Aluminum CNC Machining for Integrated Brackets and Complex Geometries? 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