Precision 6061 Gimbal Main Base Plate with Warpage Control and High-Accuracy Flange Coaxiality

We successfully manufactured a precision 6061 aluminum gimbal main base plate for an industrial UAV EO/IR payload main suspension arm application. This elongated structural base plate features a precision circular flange at the head section — presenting significant machining challenges including cutting-induced warpage in the elongated slender structure and stringent coaxiality requirements for the head circular flange. Through stress-relief machining sequences, balanced material removal, and single-setup precision boring, we delivered dimensionally stable base plates with accurate flange alignment.

Project Overview

Key Technical Highlights

• Elongated Part Warpage Control: Implemented balanced stress-relief machining sequences with symmetrical material removal across the elongated structure — preventing cutting-induced warpage and maintaining flatness ≤0.01mm across the full base plate length.
• Process Innovation:
  • Staged Roughing with Stress Relief: Roughing operations alternate across the elongated structure with intermediate stress-relief pauses before finishing — allowing stress equilibration and preventing warpage.
  • Symmetrical Material Removal: Balanced cutting patterns on both sides of the base plate distribute cutting forces evenly, minimizing residual stress-induced distortion.
  • Low-Stress Fixturing: Custom fixtures with distributed support along the full elongated length prevent clamping-induced distortion.
  • Flange Coaxiality Achievement: Circular flange bore precision-bored in single-setup reference to the established datum axis, achieving ≤0.01mm coaxiality for accurate payload rotation alignment.
• Surface Quality:
  • Precision finishing achieves Ra≤1.6μm surface finish on flange and interface surfaces.
  • Warpage-free flatness verified across full part length.

Quality Verification

Each component underwent comprehensive inspection using CMM measurement for flange coaxiality (≤0.01mm), dimensional accuracy (±0.02mm), and flatness (≤0.01mm), supplemented by surface roughness testing (Ra≤1.6μm).

Industry Applications

This solution demonstrates our expertise in precision elongated gimbal component manufacturing, ideal for:
✓ UAV EO/IR payload main suspension arms ✓ Gimbal main base plates ✓ Precision elongated structural components ✓ Payload rotation interface plates

Why Partner With Us?

• Proven expertise in elongated part warpage prevention through stress-relief sequencing
• Advanced high-accuracy flange coaxiality (≤0.01mm) capability
• Single-setup precision boring for consistent datum referencing
• 12+ years of precision manufacturing experience across UAV and optical payload sectors