A Rapid Prototype CNC Machining Case Study


Posted on Sept 25th, 2020 | By WayKen Rapid Manufacturing

Wayken Rapid Manufacturing provides rapid prototype machining services to clients from diverse industries all over the world. Especially, rapid prototype machining services are needed when custom-made parts are required in small and low-volume quantities. Using our advanced 3 and 5-axis CNC machining centers, Wayken assures high-quality parts and fast turnaround in the industry.

What’s rapid prototype machining? It often refers to CNC milling and CNC turning, both are subtractive manufacturing process. Then let’s talk about the application of rapid prototype machining and a relevant case study.

The Application of Rapid Prototype CNC Machining Services

  • Automotive: Powertrain, Automotive lighting, Chassis
  • Medical: Medical imaging
  • Aerospace: Drone,
  • Marine: Sensor, AUV, Acoustic Imaging
  • Military: Thermal camera, Imaging, and targeting sensor systems
  • High-Tech: AI, VR
  • Electronics: Remote Monitoring
  • Consumer: Glasses, Watches

A Case Study of Rapid Prototype with CNC Machining

An Indian company, who designs, builds, and develops advanced imaging and sensor systems, came to Wayken for the rugged battery pack.

rapid prototype machining
rugged battery pack

Let’s explore how the parts were made :

CNC Machining

The project consists of 85 components, CNC machining is the main process though. As it’s an outdoor product, weight is an important element when considering the material, that’s why we suggest using Magnesium for the main parts.  

The density of magnesium is almost only half of the aluminum, making it easier to carry in a bag.  As the ignition point is very low, so it has to be very careful when milling magnesium.


After milling, the machining marks and scratches might be left on the surface. To get rid of all these, all of the parts needed to be placed in a sandblasting chamber and carefully sanded, usually with #120 grit. This gives the parts a uniform finish, and burrs were removed.


Magnesium usually applies keronite instead of anodizing. Keronite refers to the use of arc discharge to enhance and activate the reaction that occurs on the anode on the basis of ordinary anodizing. The finishing treatment improves the surface hardness of the parts, which the machined-after parts more resistant in great wear, heat, and corrosion.

Powder Coating

To enhance the corrosion resistance and give the parts a bit color, the visual components were with black powder coating after keronite.

Contact Wayken to know more CNC prototyping services.

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