Precision Machining Services

Since its founding in 1984 in Ephrata, Pennsylvania, Astro Machine Works has focused on providing custom machinery and precision parts to top companies. Over the years, commitment to this vision has led to a stellar reputation, which has allowed us to expand the geographic and industry scope of our customer base. Today, we provide machines and components to leading companies across the globe. 

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Our team offers a wide range of services to meet the needs of our customers. Equipped with extensive experience and modern manufacturing equipment, we have what it takes to deliver quality solutions for simple to complex projects of small to large companies across a diverse set of industries. Below, we highlight each of our services.

We staff each project with a highly trained and experienced project manager who oversees a dedicated team of machinists, welders, electricians, etc. and serves as your primary point of contact throughout each phase until completion. Any future projects are staffed with the same manager and team, giving you continuity and comfort and enabling us to be as efficient as possible due to our familiarity with your expectations and preferences.

Services

Custom Machine Building

We design and build custom machinery for companies across a number of different industries. Our team handles all phases of the project, including: 

  • Base or frame welding and fabricating
  • Component part machining
  • Raw materials and commercially available component procurement
  • All secondary processes, such as plating and anodizing
  • Painting and specialty finishing (e.g., CARC coatings)
  • Complete mechanical assembly
  • Pneumatic or hydraulic system plumbing
  • Main control cabinet, including PLC wiring and operator stations, wiring
  • Debugging, testing, and checkout
  • Final skidding, crating, and shipping

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5-Axis Machining & Milling

Precision Machining Services

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Milling is a machining process that utilizes rotary cutting tools to shape a workpiece. During 3-axis milling operations, the workpiece can only be cut on three axes: the X-axis, the Y-axis, and the Z-axis. However, 5-axis milling allows work to be performed on two additional axes from the following options: the A-axis (rotates around the X-axis), the B-axis (rotates around the Y-axis), or the C-axis (rotates around the Z-axis). The combination of the added axes is dependent on the type of milling machine used. 

Advantages of 5-Axis Machining & Milling

Compared to other manufacturing processes, 5-axis milling has many advantages when used to create parts and products, such as: 

  • Quicker production of complex shapes
  • Higher quality surface finishes on components
  • Easier setup requirements

Industries That Utilize 5-Axis Machining & Milling Services

Some of the industries that regularly rely on 5-axis machining for the manufacture of their components include:

  • Aerospace
  • Automotive
  • Energy
  • Industrial
  • Medical

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Automated Control Panel Wiring

Our experience building custom machines provide us with the knowledge and skills needed to offer automated control panel wiring services. We can create custom panel wiring for custom machines, switch panels, touch screen control panels, and more to help automate repetitive tasks for equipment users, which can lead to increased operational safety and efficiency.

Common Components

Each control panel is custom-tailored to the unique requirements and restrictions of the equipment and its application. Some of the components commonly incorporated in the assemblies are: 

  • Programmable logic controllers (PLCs): automates control processes
  • Central processing units (CPUs): controls PLCs
  • Input/Output (I/O) cards: manages the transmission and receipt of analog/digital signals
  • PLC wiring: connects I/O cards to PLC terminals
  • Alarms: monitors systems and alerts employees to potential problems
  • Reset/emergency stop buttons: allows for system reset or shut-off in an emergency
  • Power supply: powers the assembly

Advantages of Automated Control Panel Wiring

There are a number of advantages to investing in a custom panel wiring solution for equipment, such as: 

  • Faster response time
  • Smaller footprint
  • Lower risk of leakage
  • Better space efficiency

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CNC Precision Machining

Computer numerical control (CNC) machining refers to machining operations that use computer-guided equipment to remove material from a workpiece to achieve the desired shape and size. The term encompasses a variety of processes, including CNC milling and CNC turning. 

Advantages of CNC Precision Machining

CNC machining offers many advantages over conventional manufacturing processes, including: 

  • Tighter tolerances
  • Shorter lead times
  • Reduced labor costs

Capabilities at Astro Machine Works

Our team maintains the capabilities for CNC milling and CNC turning operations. While CNC milling uses a rotating cutting tool to cut a stationary workpiece, CNC turning uses stationary cutting tools to cut a rotating workpiece. Our CNC milling capabilities include 3-axis or 5-axis milling for prototype or fully functional components. Our CNC turning capabilities allow us to produce components from various materials with visible tool marks or finished surfaces (e.g., abrasive or bead blasted). 

 

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Wire EDM

Wire electrical discharge machining (EDM) is an advanced machining technique that shapes or finishes a workpiece using electrical sparks generated by a wire electrode. It is commonly utilized to cut plates or form tools from hard materials that are not suitable for other machining processes.  

Advantages of Wire EDM

Some of the key advantages of using wire EDM to manufacture parts and products include: 

  • Lower risk of workpiece damage
  • Better surface and edge finish
  • Faster turnaround times

Wire EDM Capabilities at Astro Machine Works

We are one of the top wire EDM companies in the United States. We maintain a range of in-house capabilities, which allows us to complete a variety of EDM projects. Additionally, our continual investment in new equipment and employees enables us to stay ahead of the competition and provide customers with quality solutions. We can produce custom precision EDM components that exceed performance and quality expectations. 

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Contract Manufacturing

Contract manufacturing refers to a relationship between a company and a third-party manufacturer in which the contracting organization outsources some or all of its manufacturing operations to the contracted organization. The former may choose to form this type of partnership for several reasons, including expanding production capacities and meeting specialized manufacturing needs.

Advantages of Contract Manufacturing

A contract manufacturing partnership benefits the contracting company in numerous ways, including: 

  • Improving scalability
  • Lowering production costs
  • Freeing up resources

Industries That Utilize Contract Manufacturing

Many industries leverage contract manufacturers to produce their parts and products, including, but not limited to, the following: 

  • Aerospace
  • Automotive
  • Electronics
  • Food and beverage
  • Medical
  • Pharmaceutical
  • Robotics and automation

Capabilities at Astro Machine Works

Our team can conduct over 20,000 contract manufacturing hours per month. We can accommodate the following: 

  • All metals and alloys and as well as select non-metallic materials
  • Custom automation machinery up to 50 feet in length and 75,000 pounds in weight
  • Various structural shapes, including angles, beams, channels, plates, and tubes
  • Turning for parts up to 40 inches in diameter and 160 inches in length 
  • Milling for parts up to 118 inches x 236 inches x 47 inches
  • Surface grinding for parts up to 16 inches x 28 inches
  • Wire EDM for parts up to 23.62 inches x 15.75 inches x 19.69 inches
  • Waterjet, laser, plasma, flame, and saw cutting

Advantages of Custom Machine Building

Compared to off-the-shelf equipment, custom machinery offers significant advantages, such as:

  • Form and function that perfectly complement your facility’s existing layout
  • Capabilities aligned to your individual production requirements
  • Maximum ROI

Industries That Utilize Custom Machine Building

Some of the industries we serve with our custom machine building services include: 

  • Aerospace
  • Electronics
  • Energy
  • Food processing
  • Medical

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Machine Repair, Rebuilding, & Refurbishment

In addition to making new custom machines, we maintain the capabilities to repair, rebuild, and refurbish existing machinery. Investing in a custom rebuild or refurbishment offers the same efficiency enhancements as buying new equipment at a comparatively lower cost. Refurbishment also helps manufacturers achieve the maximum possible ROI for their expensive equipment.

Machine Rebuilding Process

A typical machine rebuilding project begins with a thorough inspection of the machine. The results of the inspection provide an accurate assessment of how much work will be required to rebuild the machine and how long it will take to complete the work. If the customer approves the recommended solution, the rebuild process can begin. The rebuild team repairs or replaces damaged components, performs resurfacing and rewiring, and installs new electronics and electrical devices as needed. 

Capabilities at Astro Machine Works

We can repair a variety of machines, including: 

  • All types of heavy machinery
  • Pneumatic and hydraulic cylinders
  • Brakes
  • Lathes
  • Grinders
  • Hydraulic presses

We can also handle CNC retrofitting tasks. 

Industries Served

We proudly provide our repair, rebuild, and refurbishment services to small, medium, and Fortune 500 companies across a range of industries, including: 

  • Aerospace
  • Energy
  • Food processing
  • General manufacturing

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Reverse Engineering

Companies using older equipment sometimes find that a critical component is no longer available. Reverse engineering enables them to create the missing piece rather than replace the entire machine. 

Reverse Engineering Application Examples

Reverse engineering can be used for various purposes, including: 

  • Redesigning a faulty component
  • Developing formal part specifications
  • Modifying and reproducing existing parts

Capabilities at Astro Machine Works

The team at Astro Machine Works has over 30 years of experience providing high-precision machine part solutions. By utilizing advanced computer-aided reverse engineering technology, we can reverse engineer parts and products quickly and cost-effectively from a sample of the worn or broken piece.

Industries That Utilize Reverse Engineering

Industries we serve with our reverse engineering capabilities include: 

  • Electronics
  • Food processing
  • General manufacturing
  • Telecommunications

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Welding & Fabrication

We use our fabrication and welding services in many of our more comprehensive projects (e.g., custom machine builds and contract manufacturing jobs). Fabrication refers to any industrial process that transforms raw material into a finished component, while welding specifically refers to processes that use heat and pressure to join metal components.

Capabilities at Astro Machine Works

Our capabilities include: 

  • Fabrication: casting, cutting, machining
  • Welding: MIG welding, TIG welding, stick welding, orbital welding
  • Finishing & testing: passivation, dye penetrant testing, specialty cleaning
  • Materials: aluminum, carbon steel, stainless steel, titanium, specialty alloys
  • Shapes: angles, beams, channels, tubes

Custom Manufacturing Solutions from Astro Machine Works

At Astro Machine Works, we specialize in precision machining and custom machine builds. Our customers range from small businesses to Fortune 500 companies, all of whom trust us to provide quality solutions. To learn more about our services or partner with us on your next project, contact us today.

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