Case Studies
Our experience spans oilfield services, petrochemical, and process industries. These cases represent a selection of our capabilities. We respect confidentiality agreements with our customers.
Chemical Injector Probe — MP35N
A client operating in aggressive oilfield conditions required a probe for injecting corrosion inhibitors into a high-pressure process pipeline. Key requirements: resistance to saline and H₂S-containing environments, precision threaded joints, durability at operating temperatures up to 250°C.
- Selected MP35N — cobalt-nickel alloy with high corrosion resistance
- CNC turned with IT6 tolerances on threaded surfaces
- PVD TiAlN coating for hydroabrasive wear protection
- Sourced check valve and fluoroelastomer O-ring seal
Part accepted without remarks. 8+ months continuous operation. Repeat order placed for 20 units.
Hydraulic Manifold — Reverse Engineering
A customer operating hydraulic equipment in harsh field conditions had a worn manifold — original OEM documentation was lost and supply was no longer available. Requirement: reverse-engineer and reproduce with improved corrosion resistance for continuous operation in aggressive environments.
- 3D scanned and built solid model of all internal channels
- Upgraded material to 17-4PH precipitation-hardening stainless steel
- 4-axis CNC milling: 14 channels, ±0.02 mm coaxiality tolerance
- EDM machining of blind cavities with complex geometry
Passed 250 atm bench testing. Material upgrade resolved original corrosion failure. Documentation retained for repeat orders.
Extruder Screw Elements — Nitrided
A manufacturer needed screw elements for a single-screw extruder-compounder. Contact with abrasive fillers at elevated temperature. OEM parts had 6+ month lead time at prohibitive cost.
- 3D scanned worn element, reconstructed nominal geometry
- Alloy structural steel with nitriding for surface hardness
- Batch of 12 on 5-axis milling center
- Hard wear-resistant surface with ductile core
Completed two service cycles. Service life comparable to OEM at significantly lower cost.
Flow Calibrator — Inconel 625, SLM + CNC
Urgent need for a large-diameter flow calibrator in Inconel 625. Bar stock procurement would take weeks. Two-piece assembly with replaceable carbide insert.
- SLM printed body from Inconel 625 — 8 days vs. 4–6 weeks for wrought stock
- CNC turning: central bore to H7 fit
- Tungsten carbide insert manufactured to specification
- Full dimensional verification with measurement report
Delivered within 3 weeks from inquiry. Two-piece design allows insert replacement without replacing assembly.