This international defense project involved manufacturing flight-certified optical lens enclosures for integration into Dassault Aviation platforms. The component, designated as the Exit Lens Housing, demanded exact concentricity and cylindrical tolerances to prevent optical misalignment under high-G flight maneuvers. Machining these housings required working with tough, corrosion-resistant aerospace steels (such as 15-5PH) that demand high tool rigidity and precise surface speed management.
Production was executed using an integrated process layout that combined turning, 5-axis milling, and precision assembly. Following the primary CNC machining stages, specialized bronze bushings were mechanically pressed into the housing bores using a custom-engineered alignment fixture to ensure absolute coaxial alignment. The interior steps and threads designed to retain the optical lenses were finished in a single setup to eliminate stacking errors and maintain perpendicularity relative to the reference datum.
The completed housings underwent 100% metrological inspection on the CMM to guarantee that all diameters and geometric relationships adhered to the Revision A engineering drawings. The components successfully passed all strict quality gates, showing no micro-vibrations or dimensional deviations. This project highlights the company's capability to deliver high-tier, multi-component assemblies directly into international aerospace supply chains.
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