Aluminum CNC Machining
Resolute Precision Manufacturing provides high-precision Aluminum CNC Machining for custom components across our multi-axis capabilities, including Swiss turning, bar-fed turning, vertical milling, and horizontal milling. Delivering tight tolerances to ±0.0005″, our aluminum machining services process 6061, 7075, 2024, and 5052 alloys from single prototypes to high-volume production releases. ISO 9001:2015 certified—direct from our shop floor to your dock. Request a QuoteWhy Aluminum is the Ideal CNC Machining Material
Aluminum is the preferred material for high-precision components when lightweight strength, high thermal conductivity, or natural corrosion resistance is critical and the application does not require heavy steel density. Through advanced aluminum CNC machining, parts can be milled and turned at significantly higher cutting speeds (SFM) and aggressive metal removal rates (MRR) than steel. This produces clean surface finishes (Ra 32–63 µin standard) with minimal tool wear, directly reducing cycle times and cost per part for complex geometries.
Combining high machinability with structural integrity, heat-treated aluminum delivers an outstanding strength-to-weight ratio, rapid heat dissipation, and ideal surface prep for anodizing. These mechanical properties make our custom aluminum machining services the preferred choice for flight-critical aerospace fittings, electronic heat sinks, robotics arm linkages, automotive housings, and industrial automation components.
Aluminum Alloy Selection Guide
The right aluminum alloy depends on the mechanical, chemical, and processing requirements of your application:
6061-T6 — A common machining alloy offering good strength, excellent corrosion resistance, and good weldability. Ideal for structural parts, housings, brackets, and general machined components.
7075-T6 — A high-strength aluminum alloy used for aerospace structural components and high-stress applications. It offers higher strength than 6061 but lower corrosion resistance and is not generally selected for welding.
2024-T3 — High strength with good fatigue resistance. Commonly used for aerospace skins, fittings, and structural components. It has limited corrosion resistance and is often clad or treated for additional protection.
5052-H32 — Excellent corrosion resistance, particularly in marine environments. It is not heat-treatable and is commonly used for sheet metal and formed components.
MIC-6 (cast tool plate) — Dimensionally stable cast aluminum plate designed for tooling plates, fixtures, and precision reference surfaces.
Specifications
| Alloys | 6061, 7075, 2024, 5052, 6063, MIC-6, and other aluminum alloys available upon request |
| Turning | Swiss CNC (20mm–38mm); bar-fed turning up to 3.2″ diameter; chucked turning up to 25.5″ diameter |
| Milling | 3, 4, and 5-axis vertical milling (up to 20″ × 50″); horizontal 4th-axis (500mm); full aluminum machining capabilities |
| Surface Finish | Ra 32–63 microinch standard as-machined; Ra 16 or better available with polishing passes |
| Tolerances | ±0.001″ standard; ±0.0005″ for precision fits; tighter tolerances available with coordinated grinding |
| Coatings | Type II and Type III hard coat anodizing, chemical conversion coating (Alodine), and paint; coordinated through qualified outside suppliers |
| Volume | 1 prototype to 500,000+ parts per year |
| Certifications | ISO 9001:2015 |
Aluminum Applications From RPM
Aluminum CNC machined components from Resolute Precision Manufacturing serve applications across multiple industries:
Aerospace: Structural brackets, fittings, and housings in 6061 and 7075
Electronics: EMI enclosures, heat sinks, and connector bodies in 6061
Robotics: Lightweight structural arms, joint housings, and motor mounts in 6061 and 7075
Automotive: Lightweight brackets, sensor housings, and sub-assembly components
Industrial: Tooling plates, fixtures, and precision reference components in MIC-6
Marine: Deck hardware, fittings, and structural components in 6061 and 5052
Industries We Serve
Aerospace & Defense
Medical Devices
Automotive
Frequently Asked Questions
Q: What is the main difference between 6061-T6 and 7075-T6 during aluminum CNC machining?
A:6061-T6 is the industry-standard general-purpose alloy offering high machinability, excellent corrosion resistance, and good weldability at a cost-effective price point. 7075-T6 provides nearly double the tensile yield strength (73 KSI vs. 40 KSI), making it the preferred alloy for high-stress aerospace and defense applications requiring maximum mechanical strength and fatigue resistance.
Q: Does RPM stock aluminum bar stock for prototype quantities?
A: Yes. We maintain stock of 6061 and 7075 aluminum round bar in common sizes for prototype and short-run production. For less common alloys and sizes, we source within one to two weeks from our material suppliers.
Q: What anodize options are available for aluminum parts from RPM?
A: Through our outside coating services, we coordinate Type II (0.0002″–0.001″ decorative anodize) and Type III hard coat anodize (0.001″–0.002″) in clear, black, and custom colors. We also coordinate chemical conversion coating (Alodine/Iridite) for parts requiring electrical conductivity through the surface treatment.
Q: Can RPM machine thin-wall aluminum sections?
A: Yes. Thin-wall aluminum machining requires appropriate fixturing and tooling to prevent chatter and deflection. We routinely machine walls as thin as 0.040″ in 6061 aluminum with appropriate process controls. Thinner walls are achievable on a case-by-case basis depending on part geometry.