CNC Machined Illuminated Dial and Pointer Assembly for the Aerospace Industry

The illuminated dial and pointer assembly shown here was designed to indicate flap positions for a commercial aircraft application.

This product demonstrates our ability to produce precision illuminated dial and pointer assemblies. The illuminated dial also contains threaded brass inserts which allow for installation into the final assembly. Each pointer shaft is torque-tested and 100% straightened, and the face of the dial and pointers are toned to ensure uniform brightness (foot-lamberts) for all the graphics.

Manufacturing required the use of precision CNC milling and turning, liquid honing, sand blasting, deburring, and annealing. Spray painting and pad printing were also applied and utilized plotter cut spray masks. Parts were also laser etched utilizing our Ytterbium Fiber Laser. The finished component measured 1.785″ in diameter and 0.607″ thick, and met tolerances of + 0.000″/ – 0.001″, and + 0.001″/ – 0.000″.

The sheer number of required materials and standards that had to be met to manufacture this component demonstrates our ability to provide precision fabrication service for the most complex components. For more information on this project, see the table below or contact us directly.

Laser Cutting Services

CNC Machining Project Highlights

Product Name

Flap Position Indicator Dial

Product Description

This illuminated indicator dial is used in the cockpit of commercial aircraft to show the position of the wing flaps.

Capabilities Applied/Processes

Primary:
CNC Milling
CNC Turning
Assembly
Spray Painting / Toning
CNC Fiber Laser Etching
Pad Printing

Secondary:
Liquid Honing
Sand Blasting
Deburring
Annealing
Cleaning
Plotter-Cut Spray Masking
Baking/Curing

Equipment Used to Manufacture Part

CNC Mill
Liquid Honing Booth
Sand Blasting Booth
Ultra Sonic Cleaner
Thermal Insert Press

Plotter / Cutter
Spray Paint Booth with Fine-Detail Spray Gun
Ytterbium Fiber Laser
Batch Oven

Overall Part Dimensions

Ø 1.785″ x 0.607″ Depth

Tightest Tolerances

+ 0.000″ / – 0.001″
+ 0.001″ / – 0.000″

Material Used

Acrylic Sheet Clear MIL-PRF-5425 (Heat Resistant)
Swage Nut, Brass, 0-80 x .088″
Insert Threaded SS 2-56 x .115
NAS662C0R2 Screw Phillips 100° Flat SS 0-80 x .125
Polken 332, Kiss-cut using Die #4034
Loctite Adhesive #4204
Lamp Board Assembly
White Epoxy Trans-Tech Type B 2NT
Blue Epoxy Tint Mix
Black Epoxy Enthone 50-series #37038
Black Lacquer Randolph R-2739
Black Lacquer Spraylat Lacryl L480
Black Epoxy Trans-Tech Type B 1MTNT
Trans Tech Black Epoxy Padprint Ink Type B 1MTNT
Clear Gloss Polyurethane MIL-PRF-85285 TY I CL H
Clear Matte Polyurethane Mix

Material Finish

Spray Painted Black FED-STD-595 Color #37038 over Translucent White FED-STD-595 Color #37875

In process testing/inspection performed

Dimensional Inspection
CMM Inspection
Visual Inspection
Photometer Luminance and Chromaticity Readings

Light Leak Inspection
Torque Test
Optical Comparator
Final Inspection

Industry for Use

Aerospace

Volume

700 per year

Delivery/Turnaround Time

16 Weeks

Delivery Location

Valley Stream, New York

Standards Met

PDF Drawing Specifications
Material Specifications
Dial brightness 0.50±0.25 foot-lamberts at 2.7±0.03 volts
Pointer brightness 0.75±0.25 foot-lamberts at 2.7±0.03 volts
Chromaticity of dial and pointer to fall within a box described by coordinates 0.527x, 0.423y; 0.497x, 0.425y; 0.484x, 0.404y; 0.513x, 0.405y on a 1931 CIE chromaticity chart
FED-STD-595 Color Specifications
Certificate of Compliance
AS9102 First Article Inspection Report