CNC Turned & Spray Painted Lexan Dial Assembly for the Aerospace Industry

The dial assembly shown here was designed and fabricated for use in an aviation application. Used as differential and altimeter indicators, these dials help the pilot to determine altitude and atmospheric pressure.

This assembly consisted of three separate dials that were assembled together and finished as a unit. The individual dials were injection molded blanks that we sourced through one of our approved suppliers. The secondary machining of the molded blanks was completed at Prime Products using a combination of CNC milling and turning with extremely tight tolerances. The parts were then de-burred, liquid-honed, annealed and thoroughly cleaned to prepare for the finishing process.

Once ready for painting, the dials were individually spray painted white using Enthone 50-110RX ink to achieve the desired light transmission of 2.7-2.8. Next, we assembled the pieces using STYCAST 1266 epoxy adhesive.

The assembly was then spray painted black with Nazdar ADE52, and tested for opaqueness on a customer-supplied fixture. Using a special process developed over many years, the white graphics were laser etched to remove the black paint while leaving the white paint in-tact.

After etching, the Amber BAC 3353 and Red BAC 1229 inks were then individually screen-printed using custom screens that were made in-house. We meticulously checked each unit for light leaks, and touched them up as necessary until the product met our customer's exacting standards.

To learn more about this project, see the table below or contact us directly.

CNC Turning & Spray Painting Project Highlights

Product Name Dial Assembly
Product Description This Differential and Altimeter Dial is used in aircrafts to help the pilot determine altitude and atmospheric pressure.
Capabilities Applied/Processes
Primary:
CNC Turning
  • Machine Gate
  • Drill 4 Holes
CNC Milling
  • Machine Gate Flush
  • Ream ID
Assembly
Spray Painting / Toning
CNC Fiber Laser Etching
Screen Printing
Secondary:
Liquid Honing
Ultrasonic Cleaning
Baking/Curing
Annealing
Equipment Used to Manufacture Part
CNC Mill
CNC Lathe
Liquid Honing Booth
Ultra Sonic Cleaner
Spray Paint Booth with Fine-Detail Spray Gun
Ytterbium Fiber Laser
Batch Oven
Overall Part Dimensions Ø 2.870" Diameter x 2.830" Depth
Tightest Tolerances + 0.000" / - 0.002"
Angles: ± 1°
Material Used Lexan Type 141-111 Mold Resin
White Epoxy Enthone 50-series 50-110RX
STYCAST 1266 Part A, Clear Epoxy Adhesive
Clear Gloss Polyurethane MIL-PRF-85285 TY I CL H
Black Epoxy Enthone 50-series Low-Carbon #37038
Amber Epoxy Tint Mix
Red Epoxy Tint Mix
Material Finish Spray Painted Black FED-STD-595 Color #37038 over Translucent White FED-STD-595 Color #37875
Graphics Amber BAC 3353 and Red BAC 1229
In process testing/inspection performed
Dimensional Inspection
CMM Inspection
Visual Inspection
Light Leak Inspection
Final Inspection
Industry for Use Aerospace
Volume 600-700 per year
Delivery/Turnaround Time 12 Weeks
Delivery Location Binghamton, New York
Standards Met
PDF Drawing Specifications
Material Specifications
FED-STD-595 Color Specifications
Certificate of Compliance
AS9102 First Article Inspection Report