When a leading manufacturer and supplier to global off-highway equipment brands needed complex machined components, they turned to Stecker Machine Company. Known for our precision CNC machining technology, skilled workmanship, and engineering expertise, Stecker was tasked with delivering a solution that met extremely tight tolerances and ensured repeatable quality at scale.
What followed was a collaborative effort that pushed Stecker’s CNC innovation. This article explores how we tackled the project’s unique demands with tailored solutions, resulting in a high-performing part, a satisfied customer, and another example of why Stecker is trusted for the CNC machining industry’s toughest jobs.
Project Overview & Challenges
Stecker was selected to machine critical hydraulic valve bodies. These essential components are used in skid loaders, backhoes, and other equipment requiring precise hydraulic control.
Looking to expand its North American supply base, the OEM identified Stecker as a top candidate after visiting our facility. They evaluated our advanced automation and engineering capabilities, and could see our commitment to quality firsthand.
The geometric dimensioning tolerance (GDT) was very tight and would be difficult to achieve for many CNC shops, but we knew we could meet specifications based on past successes. Beyond the tight tolerances were the multiple channels, bores, and intricate design of the maze-like components. Plus, they required absolute flatness. Multiple valve bodies are typically assembled together for various off-highway equipment, and must maintain pressure without leaks.
The most significant challenge, however, was meeting the customer’s stringent cleanliness specifications — any microscopic particle could cause a system failure.
Tackling Tolerances, Cleanliness & Complexity
With high production volumes anticipated, automation was a key requirement from the outset. Our team designed an efficient, high-throughput process involving raw castings machined in two robotic cell operations, followed by integrated laser engraving.
However, industrial lathes, CNC machines, and boring equipment inherently exhaust coolant and microscopic dust during operation, potentially transferring to nearby parts. Such an environment makes it difficult to meet stringent cleanliness requirements. We couldn’t have any fibers, plastic, or metallic particles greater than 500 microns. The smallest particle in a component could shut down an entire hydraulic system, leading to failure or life-threatening safety issues.
To overcome the challenge, we invested in a specialized industrial washer with multi-stage and ultrasonic cleaning cycles, ensuring every part met the highest cleanliness standards. We also invested in quality assurance equipment, including high-tech microscopes to ensure each component met specifications.
Integrating this cleaning process into automated cells was no small feat, but the result was a fully optimized production line staffed by a single operator overseeing multiple synchronized machines with high precision.
Going the Extra Mile: Ingenuity on Display
During production, our team encountered an issue known as a transition line — a visible mark left where two tool paths meet when using smaller cutting tools. The customer’s in-house solution was to grind the surface inside the machine using a grinding process to achieve a perfectly flat surface. However, this approach requires intensive man hours and creates ultra-fine dust that’s tough on equipment and difficult to manage.
The root of the problem was the tool size. Both teams were using a 3-inch milling tool, which couldn’t cover the full area in one pass. A 6-inch tool would eliminate the transition line, but there initially wasn’t enough machine travel to use it.
Stecker’s engineering team dug into the problem and developed an intricate tool path that allowed the 6-inch mill to fit and operate within the existing setup. It completely removed the transition line.
Collaboration: A Key to Success
Working with a new customer often requires balancing support with independence — and this customer struck that balance well. From the start, they were transparent about challenges they’d experienced with other suppliers and shared those insights to help everyone succeed. Weekly and biweekly meetings kept communication strong, and their team made multiple onsite visits to collaborate in real time.
Our teams worked closely to meet the project’s strict cleanliness specifications. The customer proactively identified potential issues within the automated cell setup and collaborated with the Stecker team to resolve them.
Even during early tooling trials, when questions came up mid-process, their quick, thoughtful feedback helped keep the project on track. It was a true team effort. As a provider of specialized parts with a global footprint, their name is on the line just as much as ours is, and the collaboration was a key to success for both of us.
From navigating complex tolerances and stringent cleanliness specs to engineering creative machining solutions, this project is a powerful example of how Stecker Machine Company thrives under pressure. If your components demand this level of expertise and attention to detail, it might be time to reevaluate your current machining partner. Download our guide, “When Do You Know It’s Time to Work With a High-End CNC Machine Shop?” to learn what to look for and when to make the switch. Then, get in touch.
