CNC Turned Aluminum Perforated Deflector Cone
6061-T6 aluminium deflector cones turned to a half angle within 0.1° with 3 to 24 radial ports drilled on compound angles, a wall held uniform to 0.1 mm and a base that takes a thread or a flange. Anodized inside and out where the cone sees spray, coolant or abrasive product.
- Cone Angle ±0.1°
- Ports on Compound Angles
- Wall Uniform 3 mm
- Anodized Inside and Out
*Send the spray pattern or the flow rate as well as the cone drawing. Hole size, angle and spacing are what shape the pattern, and a cone machined to the drawing can still spray in the wrong place.
Perforated Deflector Cone Overview
A deflector cone spreads flow over an area rather than a point. Its cone angle sets the spread, its ports set the distribution and its wall thickness decides whether it survives the flow it is shaping.
The cone is turned from bar with a single continuous pass so the surface has no step, then the ports are milled with the part indexed on a fourth axis so each hole is drilled normal to the local surface. Deburring is done by hand through each port because a burr inside a cone changes the pattern.
6061-T6 Aluminium Bar
6061-T6 is used because a cone is usually a low-load part where weight and finish matter: it turns to a clean surface, takes a uniform dye and does not need the strength of 7075.
7075-T6 or 316L Stainless
7075-T6 is chosen where the cone is thin and sees vibration. 316L is specified for chemical or food service, where aluminium would pit and the anodized layer would wear through at the ports.
If the media is abrasive, the material matters more than the coating: anodizing on aluminium will wear at the port edges long before a stainless cone shows anything.
Perforated Deflector Cone Specifications
Turning and milling data for cones, with the angle, port and wall values that decide whether the spray pattern lands where it was designed.
| Specification | Machining Data | Specification | Machining Data |
|---|---|---|---|
| Product | Perforated Deflector Cone / Spray Nozzle Cone | Machining Process | CNC Turning, 4-Axis Milling, Deburring |
| Material | 6061-T6 Aluminium Bar | Base Diameter | 30 – 200 mm |
| Height | 30 – 250 mm | Cone Angle | 15° – 60° Half Angle, ±0.1° |
| Wall Thickness | 2 – 5 mm | Port Diameter | Ø 3 – 20 mm |
| Port Angle Tolerance | ±0.5° | Port Count | 3 – 24 Holes |
| Surface Finish | Ra 1.6 µm Cone Face | Anodizing | Type II 15 – 25 µm |
| Customization | Slot Ports, Threaded Base, Internal Baffle, Mounting Flange | Lead Time | 5 – 7 Days Sample, 12 – 15 Days Batch |
| Inspection | Cone Angle on Shadowgraph, Port Position on CMM, Wall Ultrasonic | Packing | Foam Nest, Individually Bagged, Carton |
Key Features of Our Deflector Cones
Angle measured, ports normal to the face, edges deburred.
Cone Angle Within 0.1°
The angle is checked on a shadowgraph against the drawing, because a cone that is half a degree open spreads the pattern far wider at the target distance.
Ports Drilled Normal to the Face
Each port is drilled with the cone indexed so the drill meets the surface square, which keeps the hole round instead of oval and the spray symmetric.
Wall Measured After Porting
Wall thickness is checked at four points once the ports are cut, since a port that breaks through close to the wall is where a cone splits under pressure.
Hand Deburred Through Every Port
Each port is deburred from the inside by hand, because a burr left on the exit edge deflects the jet and shows up as an uneven pattern.
Cone that has to spread flow evenly?
Surface Finishes for Deflector Cones
The inside of the cone is the working surface and the outside is what the operator sees, so both are specified.
| Finish | Main Purpose | Finish | Main Purpose |
|---|---|---|---|
| Type II Anodizing | Corrosion protection on a part that sees spray | Hard Anodizing | Wear resistance where abrasive slurry passes |
| Masked Threads | Keeps a base thread at gauge after coating | Bead Blasting | Even matte before dye |
| PTFE Coating | Non-stick surface for sticky product build-up | Laser Marking | Cone angle and port size on the base |
*Anodizing adds 7 to 12 µm per surface, which closes a 3 mm port by about 25 µm in diameter. Small ports are drilled oversize by the coating thickness.
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Machining Process for Cones
The cone is turned in one continuous pass and the ports are drilled with the part rotated, so every hole leaves the surface at the same angle all the way round.
01. Pattern and Flow Review
Check the cone angle, port count, port size and spacing against the flow requirement, and confirm whether the base is threaded or flanged.
02. Turn the Cone
Turn the outside cone in one continuous pass with a small step-over, then bore the inside to the wall thickness, leaving the base for the last operation.
03. Drill the Ports
Index the part on a fourth axis and drill each port normal to the local surface, using a spotting drill first so the hole does not walk on the slope.
04. Deburr and Check Wall
Deburr every port from the inside, check the wall at four points and measure the cone angle on a shadowgraph before anodizing.
05. Anodize and Pack
Mask any thread, anodize inside and out, check the port diameters again after coating and pack each cone in a foam nest.
Send the cone drawing with the flow or spray pattern, and we will quote it with the angle and port layout matched to what the nozzle has to do.
Perforated Deflector Cone FAQs
Within 0.1° of half angle, measured on a shadowgraph. That matters because the pattern diameter at one metre moves by about 3.5 mm for every 0.1° of error.
Yes, each port can be at its own compound angle, machined with the part indexed. Mixed angles are common when the cone has to cover an off-centre target.
The cone splits along the port under pressure. Wall is checked after porting at four points, and a port that comes within 1 mm of the surface is flagged before anodizing.
Before, then the port is re-checked after coating. Small ports are drilled oversize by twice the coating thickness so they end up at the drawing diameter.
For large diameters, yes, but a welded cone loses the continuous surface and the weld shows in the flow. Below 200 mm base diameter, bar is cheaper and better.
Each cone sits in a foam nest with the ports clear of the foam, bagged individually. Cones shipped loose arrive with dented port edges that change the pattern.
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