Examples from production programs showing how manufacturing challenges were resolved to achieve stable, repeatable output.
Component: SS316/1.4401 valve housing
Industry: Industrial valves
Region: Western European OEM
Process: Investment Casting
Challenge: Subsurface porosity became visible during machining, affecting pressure integrity and increasing rejection during production.
Approach: Process evaluation indicated gas entrapment linked to mould behaviour and metal flow stability. Gating design was refined, mould permeability was improved, and melt control practices were strengthened to minimise internal gas retention.
Outcome: Stable internal quality achieved, enabling reliable pressure performance and reduced production variability across batches.
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Component: 4130 alloy steel valve body
Industry: Oil & gas equipment
Region: Texas, USA
Process: Closed Die Forging + Heat Treatment
Challenge: Internal folds detected during ultrasonic testing created structural risk and increased rejection in high-pressure service components.
Approach: Process evaluation identified instability in material deformation behaviour during forging. Die geometry was refined, forging temperature control was tightened, and lubrication practices were improved to minimise fold formation.
Outcome: Improved internal integrity and consistent ultrasonic performance, enabling reliable production for high-pressure applications.
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Component: SS304L/1.4306 thin-walled sleeve
Industry: Industrial pumps and valves
Region: Italy
Process: Precision CNC Machining
Challenge: Thin-walled components exhibited loss of roundness after machining due to clamping-induced deformation.
Approach: Workholding strategy was redesigned to distribute clamping forces more evenly, combined with staged machining passes and vibration-controlled tooling to stabilise geometry.
Outcome: Stable circularity achieved with consistent dimensional performance across repeat production.
