FastPreci partnered with Race-Ing. Team FH Dortmund to provide custom manufacturing solutions for high-precision racing components. This project involved 48 custom parts (211 total pieces) produced in two batches, requiring a combination of 5-axis CNC machining, CNC turning, WEDM wire cutting, and metal 3D printing.
We processed a wide range of engineering materials, including EN AW-7075-T6 aluminum, 25CrMo4, 42CrMo4, 34CrNiMo6, and AlSi10Mg, while maintaining ISO 2768-MK tolerances and Ra 3.2 surface finish requirements.
Challenges in Manufacturing Complex Racing Components
This project highlighted several challenges involved in manufacturing complex racing components with tight tolerances and demanding performance requirements:
- 48 unique part designs, 211 components across five material grades and four manufacturing processes, with most parts produced in single-digit quantities.
- Drawing revisions and newly introduced part designs were incorporated during production within an overall project lead time of approximately one month.
- Topology-optimized parts and complex multi-face geometries requiring either metal additive manufacturing or single-setup 5-axis machining.
- Hybrid machining workflows combining CNC turning with subsequent 5-axis milling.
- Thin-walled (~1 mm) high-strength alloy components susceptible to machining deformation.
- Critical functional features on selected parts required dedicated GD&T controls beyond the general ISO 2768-mK tolerances. For example, the Rocker Attachment featured a Ø26 H7 bearing bore with a 0.05 mm positional tolerance.
These challenges required not only machining capability, but also strong DFM (Design for Manufacturability) support and flexible production planning.
Custom Manufacturing Solutions for Complex Racing Components
To address these challenges, FastPreci implemented an integrated CNC machining and multi-process manufacturing strategy:
- DFM Optimization for Improved Manufacturability
We provided proactive DFM recommendations by replacing sharp internal corners with R5 radii on key parts such as the oil pan and brake pedal baseplate. This optimization improved tool accessibility, reduced stress concentration, and enhanced manufacturability. The customer reviewed and approved these design improvements before production. - 5-Axis Machining for Complex Multi-Face Features
For critical EN AW-7075-T6 aluminum components, we applied full 5-axis CNC machining to complete multi-face features in a single setup. This significantly reduced repositioning errors and ensured high precision in bearing bore concentricity, which is essential for racing performance. - CNC Turning and 5-Axis Machining Integration
Some components required initial CNC turning followed by 5-axis machining. We optimized the process flow to maintain datum consistency and minimize cumulative tolerance deviations throughout production. - WEDM Wire Cutting for Thin-Walled Alloy Steel Parts
A complex 34CrNiMo6 component with thin and irregular geometry was manufactured using WEDM instead of conventional milling. This approach effectively avoided deformation and improved dimensional stability in high-strength steel machining. - Metal 3D Printing for Complex Geometries
Selected parts were produced using AlSi10Mg aluminum via additive manufacturing, reducing machining complexity and improving overall production efficiency.
Results: High-Precision Racing Components Delivered
These custom manufacturing solutions enabled the project to meet demanding performance, quality, and delivery requirements.
- All machined parts met ISO 2768-MK tolerances and Ra 3.2 surface finish
- Stable delivery across two production batches despite design revisions
- Excellent assembly performance with precise fitment in the racing system
- Improved machining efficiency through 5-axis CNC and DFM optimization
- Reduced risk in machining high-strength alloys and complex geometries
Customer Feedback on Manufacturing Quality and Support
“Hello Adela, yes the parts fit perfectly thank you very much also for the service and fast replies!”
“The parts from the second order finally arrived last week and everything looks good so far!”
——Markus, Technical Leader
Key Manufacturing Capabilities Highlighted
- 5-axis machining for complex racing components and tight-tolerance geometries
- Machining of high-strength alloys, including 7075-T6 aluminum, 34CrNiMo6, and 42CrMo4
- Integrated manufacturing capabilities combining CNC machining, WEDM, and metal 3D printing
- Engineering collaboration and DFM support from prototype review to low-volume production
- Agile manufacturing support for evolving designs and fast project iterations
Conclusion
This racing components project demonstrates how fast, flexible, and engineering-driven custom manufacturing solutions can support performance-critical applications. By combining 5-axis CNC machining, CNC turning, WEDM wire cutting, and metal 3D printing, we were able to produce complex racing components with stable quality, even as the customer updated drawings during production.
Just as importantly, our workflow is built around a controlled quality management approach, including document review, drawing verification, dimensional inspection, traceability, and clear handling of any nonconforming issues. This ensures that the parts delivered are not only manufacturable but also ready for reliable assembly and real-world racing applications.
Need custom manufacturing solutions for prototype racing components with tight tolerances, complex geometries, and fast engineering feedback? Send us your drawings for a DFM review. Our team can help optimize your design, select the right manufacturing process, and improve manufacturability before production begins.
Whether your project involves 5-axis CNC machining, WEDM, CNC turning, or hybrid manufacturing for motorsport and components, we support both prototyping and low-volume production with responsive communication and quality-controlled delivery.
FAQ
What manufacturing processes were used in this project?
We used CNC machining, 5-axis CNC machining, CNC turning, WEDM wire cutting, and metal 3D printing, depending on the part geometry and material requirements.
Why was 5-axis machining important for this project?
5-axis machining allowed multi-face features to be completed in a single setup, which reduced repositioning errors and helped maintain high concentricity for critical bearing bore features.
How was quality controlled?
The quality approach followed a structured IQC-style workflow: incoming document verification, drawing and requirement review, sampling-based inspection, dimensional and visual checks, clear pass/fail decisions, and traceable records for every lot.
What should I send for a quote or DFM review?
Send the 2D drawing, 3D CAD file, material specification, tolerance requirements, surface finish requirement, quantity, and any special notes on critical features or assembly needs. Our engineering team will recommend the most suitable custom manufacturing solution based on your design, tolerances, materials, and production volume.
