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Case Studies

Real results from real manufacturers — documented improvements in tool life, cycle time, and cost-per-part across hydraulics, aerospace, medical, and automotive applications.

50+

Countries Served

200+

Custom Tool Projects

3×

Avg. Tool Life Gain

40%

Avg. Cost Reduction

Hydraulics

Major Hydraulic OEM — USA

Hydraulics

Cavity Tools

Sun Hydraulics T-Series Cavity Tools: 3× Tool Life Improvement

Challenge

A leading US hydraulic manifold manufacturer was replacing imported cavity tools every 150 pieces due to premature edge chipping on D03 and D05 body bores machined in 316 stainless steel. Total tool cost was exceeding $12 per manifold.

Solution

JIAYI engineered a custom K20 submicron carbide cavity tool with a 0.2 µm Ra edge prep and AlTiN-X coating. Geometry was optimized for interrupted cuts typical in manifold porting with a 12° positive rake and reinforced corner radius.

Results

Tool life increased from 150 to 480 pieces — 3.2× improvement
Tool cost per manifold reduced from $12.00 to $3.80
Surface finish improved from Ra 1.6 to Ra 0.8 µm
No process changes required — drop-in replacement

Aerospace

Tier-1 Aerospace Supplier — Germany

Aerospace

Reamers

PCD Reamer for Ti-6Al-4V Structural Components: 60% Cycle Time Reduction

Challenge

A German aerospace tier-1 was machining precision holes in Ti-6Al-4V wing rib components. Their existing HSS-Co reamers required 3 passes at 8 m/min to achieve H7 tolerance, resulting in 4.2-minute cycle time per hole and frequent regrinding.

Solution

JIAYI developed a 6-flute PCD reamer with 15° helix, polished flutes, and diamond-coated margins. The tool was qualified to aerospace PPAP Level 2 with full dimensional traceability.

Results

Cycle time reduced from 4.2 to 1.7 minutes per hole — 60% reduction
Cutting speed increased from 8 to 25 m/min
Tool life: 2,200 holes vs 380 holes for HSS-Co
PPAP approved on first submission

Medical

Medical Device Manufacturer — Switzerland

Medical

Drills

Micro Carbide Drills for Surgical Instrument Components

Challenge

A Swiss medical device OEM required ⌀0.8 mm through-holes in 17-4PH stainless steel bone screw components to ±0.005 mm positional tolerance. Breakage rates with existing tools were 12%, causing significant scrap and downtime.

Solution

JIAYI produced K10 submicron carbide micro drills with a 130° split-point geometry, TiCN coating, and polished flutes. Specialized packaging with individual foam inserts prevented edge damage in transit.

Results

Breakage rate reduced from 12% to under 0.5%
Positional tolerance consistently within ±0.003 mm
Tool life: 800 holes per drill vs 220 previously
Scrap rate on component reduced by 94%

Automotive

Tier-2 Automotive Supplier — Mexico

Automotive

Thread Mills

Thread Milling vs Tapping: 40% Cost Savings on Transmission Housing

Challenge

A Mexican automotive supplier was producing M10×1.5 threaded ports in AlSi9Cu3 transmission housings. Tapping tool breakage inside cast threads was causing 8% scrap rate and frequent spindle crashes.

Solution

JIAYI designed a 3-flute solid carbide thread mill with K20 substrate, TiAlN coating, and helical flute for chip evacuation. A single-pass thread milling cycle replaced tapping, eliminating breakage risk entirely.

Results

Scrap rate reduced from 8% to 0.2%
Eliminated spindle crash risk — no tool breakage possible
Cost per thread reduced by 40% including tooling amortization
Same thread mill handles M8, M10, and M12 with program change only

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