Pharmaceutical
The Challenge
A pharmaceutical customer required the manufacture of highly precise flow cells used in analytical and testing applications. These specialized components play a critical role in monitoring drug purity, dissolution rates, and cellular interactions, making dimensional accuracy and surface quality essential.
The project presented several manufacturing challenges. The parts required an exceptionally smooth 15 Ra surface finish along with electropolishing to meet stringent pharmaceutical industry standards. In addition, some of the flow cells were produced from C-22 Hastelloy, a highly corrosion-resistant superalloy known for its strength and machining difficulty. Tight tolerances, complex geometries, and demanding finish requirements made precision and process control critical throughout production.
The Solution
SF Machining partnered closely with the customer from the outset, utilizing customer-supplied drawings, prints, and 3D solid models to develop optimized CAD/CAM programs and highly accurate machining strategies. Customized tool paths were created to maximize precision while maintaining efficiency throughout the manufacturing process.
Production incorporated multiple machining disciplines, including CNC turning, live tooling and 4th-axis machining, vertical milling operations, and wire EDM processing through a trusted specialty partner. To achieve the required surface finish, experienced internal diameter and outer diameter polishing specialists carefully finished critical features, including difficult-to-access areas of the components.
Throughout the project, SF Machining worked collaboratively with the customer to verify print dimensions, clarify assumed tolerances, and ensure manufacturability. Electropolishing was performed through an experienced finishing partner, while laser marking was completed according to customer specifications. Full raw material heat-number traceability was maintained for every production lot, providing complete documentation and quality assurance.
The Results
The completed flow cells met all customer specifications and were approved for use in pharmaceutical applications.
The success of the initial production runs led to repeat orders and an ongoing manufacturing relationship. Insights gained during prototype and early production stages also contributed to design refinements, resulting in updated print revisions that improved both manufacturability and long-term performance.
In-House Manufacturing Advantage
Whether your project requires a uniform brushed finish, weld blending, deburring, or a high-luster polish, we focus on precision, consistency, and fast turnaround times at every stage of production.
Built for Quality & Reliability
When finish quality matters, S&F delivers the detail, consistency, and craftsmanship your project demands.
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