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 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

CNC Turning

  • Machine Gate
  • Drill 4 Holes

CNC Milling

  • Machine Gate Flush
  • Ream ID

Spray Painting / Toning
CNC Fiber Laser Etching
Screen Printing

Liquid Honing
Ultrasonic Cleaning

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



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