Custom Billet Machining

What is Custom Billet Machining?

Billet machining starts with a solid block of metal called a “billet.” We use special computer-controlled machines to cut away the extra material until we get the exact shape needed. This is perfect when you need strong, precise parts without any weak spots.

Materials We Work With

We can machine many different materials to fit your exact needs:

Need aluminum CNC machining for your next project? Istar Machining specializes in creating perfect aluminum parts!

Our Precision Capabilities

When you need parts that fit perfectly, our tolerance levels make all the difference:

• Ultra-precise measurements down to ±0.0005″ (thinner than a human hair!)
• Surface finishes that look and feel just right
• Complex shapes that other machine shops can’t make

For the most demanding projects, our 5 axis machining service can create almost any shape imaginable!

Industries We Serve

Aerospace

We make parts that fly! Our aerospace parts meet strict AS9100 standards for safety and quality. From small brackets to complex housing parts, we help keep aircraft safe and reliable.

Automotive

Race cars and high-performance vehicles need the strongest, lightest parts possible. Our custom billet parts can help engines make more power while lasting longer.

Medical Devices

We create surgical-grade parts for medical equipment that must work perfectly every time. These parts often help save lives!

Industrial Equipment

Factory machines need tough parts that won’t break down. Our billet machined parts keep production lines running smoothly.

Our Advanced Equipment

At Istar Machining, we use the best machines to make your parts:

• 5-axis CNC mills that can cut from almost any angle
• Swiss-style lathes for super-precise round parts
• Wire EDM for making very detailed shapes
• CMM machines that check every dimension precisely

Need parts with complex 3D shapes? Check out our 3D CNC machining services!

The Billet Machining Process

Here’s how we turn blocks of metal into amazing finished parts:

1. Design Phase: We review your drawings or help create them
2. Material Selection: We choose the perfect metal for your needs
3. CNC Programming: Our experts program the cutting paths
4. Machining: Our CNC machines cut away the extra material
5. Quality Control: We check every part to make sure it’s perfect
6. Finishing: We add special treatments like anodizing if needed
7. Final Inspection: One last check before shipping to you

Why Choose Billet Machining?

Billet machining has some big advantages over other ways to make parts:

• Stronger parts with no weak spots from welding or casting
• Perfect accuracy every time
• No special tooling costs for small batches
• Complex shapes that can’t be made any other way
• Fast turnaround for urgent projects

Surface Finishes

After machining, we can add special finishes to your parts:

• Anodizing for aluminum (colors available!)
• Polishing for a mirror-like shine
• Powder coating for tough, colored surfaces
• Passivation to prevent rust on stainless steel
• Hard coating for extreme wear resistance

Quality Assurance

At Istar Machining, quality is our top priority:

• ISO 9001 certified quality systems
• AS9100 certified for aerospace work
• CMM inspection of critical dimensions
• Material certifications provided
• Full traceability of all materials and processes

Custom Thread Machining

We can add perfect threads to your parts with our CNC thread milling capabilities:

• Standard threads: UNC, UNF, Metric, NPT
• Custom threads: Special sizes and pitches
• Internal and external threading options
• Left-hand or right-hand threads available

Design Support

Not sure if your design will work? Our team can help:

• Design for Manufacturing (DFM) review
• CAD/CAM support and file conversion
• 3D model creation from 2D drawings
• Reverse engineering of existing parts

Lead Times and Flexibility

When you need parts fast, we deliver:

• Rush service available (72-hour turnaround for emergencies)
• Prototype to production scaling
• No minimum order quantities for prototypes
• Volume discounts for larger orders

Cost Factors in Billet Machining

Several things affect the price of billet machined parts:

• Material type and size
• Complexity of the design
• Tolerances required
• Surface finish needed
• Quantity ordered
• Inspection requirements

Applications of Custom Billet Parts

Our machined parts are used in many important products:

• Engine components for race cars
• Aircraft structural parts
• Medical device housings
• Robotic arm components
• Hydraulic system blocks
• Scientific instrument parts

Need parts that can withstand extreme conditions? Our titanium CNC machining creates parts with incredible strength-to-weight ratios!