Case Study

Complex Structural Part Demo — Aerospace-Grade Surfaces in 72h

Aerospace Confidential Aerospace Prototype Program

Key Challenges

Freeform structural bracket (850 mm × 650 mm × 45 mm, 2.5 mm walls) required multi-axis machining, 150+ threaded holes, and aggressive weight reduction while minimizing scrap.

Solution

Geppetto’s AI CAM generated optimized 5-axis toolpaths, paired with apprentice execution and expert QA to balance precision and material utilization.

Precision
Met project-specific tolerance across entire surface
Cost Saving
30–40% estimated cost reduction via material + cycle optimization
Delivery
72h production + logistics
Quality
Material utilization improved from 12% to >30%
Demonstration project for capability showcase; aerospace certification requirements handled per program.

Program Context

The customer needed a structural prototype to validate topology-optimized designs under aggressive timelines. Traditional vendors quoted 30 days just for CAM programming.

Manufacturing Obstacles

  • Large-format freeform surfaces with intersecting ribs.
  • Thin walls created vibration and deformation risks.
  • Raw billet (15 kg) had to be reduced to 1.2 kg finished weight.
  • 5-axis programs would normally take weeks to perfect.

Geppetto Solution

  1. AI CAM core: Our system recognized features automatically, produced collision-free multi-axis paths, and predicted cycle times.
  2. Material strategy: Intelligent stock planning and adaptive roughing increased utilization and reduced scrap.
  3. Quality supervision: Senior machinists monitored vibration and thermal drift while CMM checkpoints kept geometry in spec.

Outcome

  • Lead time: Quote in 8h, machining and finishing completed within 72h.
  • Precision: Surface deviation stayed within ±0.01 mm, matching structural analysis needs.
  • Data package: Delivered detailed machining logs, QA reports, and optimization notes for the customer’s digital thread.

Business Impact

The aerospace team proved manufacturability before entering wind-tunnel testing, saving weeks of schedule risk and providing concrete data for executive buy-in.***

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