Five Axis CNC Machined Aluminum Frame Segments
Frame segments machined on simultaneous five-axis centres from 6061-T6, with the profile held to ±0.03 mm of the model, compound faces at ±0.05°, mating faces flat to 0.02 mm and pairs matched within 0.03 mm and packed together.
- Compound Angles in One Set-up
- Profile Held to 0.03 mm
- Pairs Matched Within 0.03 mm
- No Re-clamping Marks
*Send the 3D model with the datum scheme, not just a 2D drawing. A compound face defined only by two views leaves the blend radius open, and the mating part will not sit flush.
Five Axis Machined Frame Segments Overview
These segments form a joint on a machine frame where two planes meet at a compound angle. The joint only closes if both faces are cut from the same set-up, because re-clamping moves the second face by a few hundredths.
The blank is roughed on three axes, then finished on a five-axis centre with a barrel cutter on the blend, so the transition from one face to the next is continuous and the corner radius matches the model.
6061-T6 Aluminium
6061-T6 is stiff enough at a 3.5 mm wall for a frame segment and anodizes evenly over a curved surface, which matters when two segments sit next to each other in different colours.
7075-T6 or 5083
7075-T6 is used at the pivot where the load is concentrated, and 5083 is chosen for segments that are welded into a gantry, since it keeps strength in the heat-affected zone.
Under a 3.5 mm wall the segment rings when the frame is loaded, and the anodized face shows a ripple that no amount of polishing removes.
Frame Segment Specifications
Five-axis finishing data for frame joints, with the profile and pair-match values that decide whether a joint closes.
| Specification | Machining Data | Specification | Machining Data |
|---|---|---|---|
| Product | Frame Segment Set with Compound Faces | Machining Process | 5-Axis Simultaneous CNC Milling |
| Material | 6061-T6 Aluminium, 15 – 30 mm Plate | Envelope | Up to 260 × 120 × 60 mm |
| Profile | ±0.03 mm to the Model | Compound Angle | ±0.05° from the Datum |
| Face Flatness | 0.02 mm on Mating Faces | Wall Thickness | 3.5 mm Minimum |
| Bolt Holes | M5 / M6, Position ±0.05 mm | Hole Axis | Normal to the Local Face Within 0.2° |
| Pair Match | Faces Within 0.03 mm of Each Other | Edge Break | 0.4 mm on All Machined Edges |
| Weight | 180 – 620 g per Segment | Coating Build | 15 – 20 µm Anodizing |
| Customization | Colour, Angled Interface, Cable Channel, Pair Orientation | Lead Time | 8 – 10 Days Sample, 16 – 22 Days Batch |
| Inspection | CMM Scan Against the Model, Pair Match Check, Thread Gauges | Packing | Pair Bagged Together, Foam Divider |
What Five-Axis Brings to These Segments
One set-up for compound faces, barrel-cut blends, pairs measured together.
Compound Faces in One Set-up
Both angled faces are finished without unclamping, so their intersection stays within 0.03 mm and the segment seats on two planes without a shim or a file.
Barrel Cutter on the Blend
The transition between the two faces is cut with a barrel cutter rather than a ball nose, which gives a continuous radius instead of a ring of scallops that shows through the anodizing.
Holes Normal to the Local Face
Bolt holes are drilled on the tilted axis so each screw seat is square to its own face within 0.2°, which stops a cap screw from pulling the joint out of line.
Pairs Machined and Checked Together
Left and right segments are cut from one blank, measured as a pair and packed together; mixing pairs from different batches leaves a 0.05 mm step at the joint.
Joint that has to close without shims?
Finishes for Frame Segments
Colour is often functional here, but the mating faces always stay bare.
| Finish | Main Purpose | Finish | Main Purpose |
|---|---|---|---|
| Clear Anodizing | Protection with machined faces visible | Red Anodizing | Colour-coded frame segments |
| Black Anodizing | Machine frame and gantry parts | Hard Anodizing | Wear faces at the pivot |
| Bead Blasting | Even matte over a 5-axis surface | Masked Interfaces | Mating faces stay bare |
| Laser Marking | Segment number and orientation | Colour Match | Batch-to-batch dye control |
| Pair Check | Both halves measured together | Face Film | Peel coat on mating faces |
| Salt Spray | 500 h on 6061 | Pair Match Recheck | Both Halves After Coating |
*Anodizing builds 15 to 20 µm on every face; mating faces are masked so the joint closes on metal, not on two layers of oxide that crush unevenly.
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Machining a Five-Axis Frame Segment
The compound faces are cut in one five-axis set-up, so the segment seats on two planes at once instead of being re-clamped and blended by hand.
01. Model and Datum Review
Read the 3D model, agree the datum scheme and identify which faces mate, then plan the set-up so no mating face needs re-clamping.
02. Rough on Three Axes
Rough the blank on a three-axis mill leaving 0.6 mm on all faces, which removes most of the material before the slower five-axis pass.
03. Finish on Five Axes
Finish the compound faces and the blend in one continuous five-axis path with a barrel cutter, keeping the tool normal to the surface throughout.
04. Drill on Tilted Axes
Drill and tap the bolt holes normal to each local face, then ream the dowel holes from the primary datum so pairs locate on the same pins.
05. Measure, Mask, Anodize
Scan the part against the model on a CMM, check the pair match, mask the mating faces, anodize and pack each pair together.
Send the 3D model and tell us which faces mate, and we will quote segments finished in one five-axis set-up with the pair matched before coating.
Five Axis Frame Segment FAQs
Because the compound angle needs two re-clampings, and each one moves the part by 0.02 to 0.05 mm. The joint then needs a shim, which is exactly what a five-axis part avoids.
±0.03 mm against the model on a scanned surface, with the compound angle within ±0.05°. Tighter than that needs the model tessellated to the same tolerance.
Yes, from a scan of the mating part. We build the model from the scanned surface rather than the nominal drawing, which is what a retrofit needs.
With a barrel cutter on a continuous path at 0.15 mm step-over, then a light bead blast before anodizing. A ball nose at the same step-over leaves visible scallops.
Eight to ten days for a sample, because the five-axis path has to be proven on the first part and the CMM scan compared with the model before the batch runs.
Yes, and they are always measured as a pair. Two right-hand segments from different batches will not close a joint to better than 0.05 mm.
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