Intricate five-axis geometry alongside a metre of prismatic work. AIM’s milling capability spans both — simultaneous 5-axis machining for complex, multi-face components, and large-format vertical milling for heavy structural parts — each cut to drawing, measured and traced within a single controlled process in Lichfield.
Milling Capability
Complex Geometry and Large-Format Capacity
Requirements range from small, geometrically complex parts to large, heavy prismatic ones — all machined in-house, so a component never has to be split across suppliers to find the capability or the capacity to match.
Simultaneous 5-Axis Machining
Tool and part move across all five axes at once on a tilt-and-rotate table, reaching compound angles and deep features in a single set-up. Ideal for engine and propulsion parts, impellers and bladed forms, and difficult-access ports.
Large-Format Vertical Milling
For heavy prismatic work — baseplates, manifolds, valve blocks and structural housings machined complete rather than in sections. Capacity also lets us fixture several smaller components together for efficient batch running.
Five-Axis
Why Five Axes Change the Part
Five-axis machining is not simply about reach. Presenting the part to the tool at the right angle changes what can be held, how accurately features relate to one another, and how good the finished surface is.
01
Fewer Set-Ups
Machining several faces in one clamping removes the small errors that accumulate each time a part is unclamped, repositioned and re-zeroed — and shortens the route.
02
True Feature Relationships
Holes, faces and datums cut in the same set-up hold their positional and angular relationships far more tightly than features split across separate operations.
03
Shorter Tools, Better Finish
Tilting the part lets us reach deep features with shorter, more rigid cutters — less deflection, cleaner surfaces and more consistent tolerances.
Accuracy
Tolerance, Finish and Repeatability
Our milling capability is maintained and programmed to hold tight, repeatable tolerances on suitable features. Achievable tolerance depends on the feature, material, workholding and inspection method, so it is confirmed against your drawing at quotation rather than assumed — and then verified as the part is made.
- Close tolerances on critical dimensions, tighter by agreement
- Fine machined surface finishes where the drawing calls for them
- Consistent feature-to-feature relationships from single-set-up machining
- Geometric tolerances (GD&T) interpreted from your drawing and datum scheme
- Repeatable results across prototype and repeat batches
- Capability confirmed by first-off and in-process measurement
Materials
Materials We Mill
Subject to a technical review of geometry, tolerance and heat-treatment condition, AIM mills a broad range of metals and engineering plastics:
- Aluminium and aluminium alloys
- Carbon and alloy steels
- Stainless steels
- Tool steels
- Cast iron
- Copper, brass and bronze
- Titanium and specialist alloys
- Engineering plastics
Applications
What We Mill
From one-off development hardware to repeat production, typical milled components include:
- Aerospace brackets and structural parts
- Engine and propulsion components
- UAV and airframe fittings
- Multi-face housings and covers
- Manifolds and valve blocks
- Baseplates and mounting plates
- Impellers and bladed forms
- Automation and machine components
- Mould and tooling inserts
- Jigs and inspection fixtures
Process
Operations in a Single Set-Up
Where the geometry allows, roughing through to finishing features are combined in one controlled operation, reducing handling and keeping features true to one another:
- Face and profile milling
- Multi-face machining
- Complex contouring
- Pocket and cavity machining
- Slotting
- Precision boring
- Drilling and reaming
- Tapping and thread milling
- Chamfering
- Angled-feature machining
Critical features are verified against the drawing as the part is made — first-off, in-process and final — with CMM measurement and First Article Inspection documentation available through our inspection and CMM capability.
Programming
From Your CAD Model to a Finished Part
Components are programmed with modern CAM and full toolpath simulation, so cutting strategy, tool access and collision clearance are checked before a machine is cut. We work from your 3D model or 2D drawing and can feed back on manufacturability first:
- Native and neutral 3D CAD — STEP, IGES, Parasolid and common formats
- 2D drawings in PDF or DXF for dimensions, tolerances and datums
- CAM toolpath development for 3-axis and simultaneous 5-axis
- Toolpath simulation and collision checking before cutting
- Design-for-manufacture feedback ahead of production
- Proven programs stored and re-run for repeat orders
Volume
Prototype to Production
The same controlled process and inspection route covers every quantity, so a part proven at prototype runs the same way in production:
- One-off development and prototype parts
- Bridge manufacturing ahead of hard tooling
- Low- and medium-volume production
- Repeat and scheduled batches
- Legacy and replacement parts
- Multiple parts fixtured together for efficiency
FAQ
CNC Milling — Frequently Asked Questions
How large a component can AIM CNC mill?
Simultaneous 5-axis components are accommodated up to approximately Ø500 × 350 mm with a combined component and fixture load of up to approximately 300 kg. Larger prismatic work is machined up to approximately 1,300 × 670 × 625 mm with table loading up to approximately 1,300 kg. Machine travel does not automatically equal finished-part size — workholding, spindle clearance and tool access are confirmed at quotation.
What is the difference between 3-axis and simultaneous 5-axis milling?
In 3-axis milling the cutter moves along three linear axes and the component is re-fixtured to reach each face. Simultaneous 5-axis milling adds two rotary axes, so the tool and part move together and several faces and compound angles are machined in one set-up. This means fewer re-fixtures, tighter relationships between features on different faces, and access to complex geometry that is difficult to reach on a 3-axis machine.
Which materials can AIM mill?
Subject to technical review, AIM mills aluminium and aluminium alloys, carbon and alloy steels, stainless and tool steels, cast iron, copper, brass, bronze, titanium and specialist alloys, and engineering plastics. Material suitability is assessed against component geometry, tolerance, tooling and heat-treatment condition.
Can AIM mill prototypes as well as production batches?
Yes. Our milling capability supports one-off development parts, prototypes, low-volume production, bridge manufacturing and repeat batches, all run through the same controlled process and inspection route.
How are milled components inspected and documented?
Critical features are verified against the drawing first-off, during machining and at final inspection. CMM measurement, dimensional reporting and First Article Inspection (FAI) documentation are available, and inspection requirements are agreed before machining begins.
Does AIM machine aerospace and defence components?
Yes. AIM mills components for aerospace, defence, UAV, energy and industrial applications, and is developing its quality-management system in alignment with AS9100D. AIM is working towards AS9100D certification and does not currently represent itself as AS9100D certified.