Effective Separation of Complex Components – Ensure Functionality, Optimize Manufacturing

Effective Separation of Complex Components – Ensure Functionality, Optimize Manufacturing

In precision turning, increasingly complex geometries and tight tolerances are being demanded—often alongside rising requirements for weight reduction, precision and cost-efficiency. One effective method for optimization: strategically dividing a complex component into several functionally coordinated individual parts.

Core Principle: Think Modular Functionality

If the function allows, breaking down a component into multiple parts often offers clear advantages—both in terms of manufacturing and performance. This enables the use of more economical production methods and allows for reductions in material usage and overall weight.

Practical Example: Control Spool in a Hydraulic Application

A typical case: A one-piece control spool with a flange of Ø13 mm creates several technical challenges:

• High operational weight due to the flange
• Cost-intensive grinding operation required (plunge grinding)
• Tool requirements for deep, precise drilling of small diameters

Alternative: Division into Three Individual Parts

The functions of the original component are modularized and distributed across three separate elements:

1. Sleeve

• Outer contour can be economically ground using through-feed grinding
• Easier machining with standard processes

2. Nozzle Insert

• Separate part with reduced diameter and length
• Easier to produce due to better accessibility and shorter tool overhang

3. Stop Disc

• Pressed onto the sleeve
• Mechanically fixes the position without additional machining steps

Key Advantages at a Glance:

• Reduced operational weight by separating the large flange
• Lower manufacturing costs through more economical machining methods (e.g., through-feed grinding instead of plunge grinding)
• Easier tool access for internal machining of small diameters
• Improved process reliability by eliminating critical machining steps in hard-to-reach areas

Conclusion: Multi-Part Designs Can Be More Economical

Not every component needs to be manufactured as a single piece. Through smart functional separation into multiple parts, complex components can be produced more easily, more cost-effectively and in many cases even with improved functionality.

As specialists in precision turned parts, we don’t just think in geometries—we think in ready-for-production solutions. Get in touch if you’d like to unlock new potential in your design.