MECHANICAL FABRICATION

Calpak USA provides comprehensive sheet metal fabrication services at our Hawthorne, California facility including precision cutting, CNC punching, bending, forming, welding, and hardware insertion. We work with a range of materials including aluminum, stainless steel, cold-rolled steel, and galvanized steel in thicknesses from 0.020 inches to 0.250 inches. Our sheet metal capabilities support enclosure fabrication, brackets, chassis, panels, mounting plates, and custom mechanical components for electronics integration. All sheet metal work is performed under our AS9100 Rev. D quality management system with full dimensional inspection and material traceability.

Calpak USA operates CNC milling equipment for producing precision mechanical components, fixtures, and custom parts. Our milling capabilities include 3-axis machining of aluminum, steel, brass, copper, and engineering plastics such as Delrin, PEEK, and G-10. Typical CNC-milled parts include heatsinks, adapter plates, test fixture bodies, connector panels, and mechanical housings that integrate with our electronic assemblies. We hold tolerances to ±0.001 inches on critical dimensions. CNC milling is performed in-house at our Hawthorne, California facility, allowing tight coordination between mechanical fabrication and our electronics assembly operations for turnkey delivery.

Calpak USA fabricates parts from a wide range of metals and engineering plastics. Commonly processed metals include 6061 and 7075 aluminum, 303 and 304 stainless steel, cold-rolled steel, and brass. For non-metallic applications, we machine engineering plastics including Delrin (acetal), PEEK, Ultem, nylon, polycarbonate, and G-10/FR-4 laminate. Material selection is driven by your application requirements — weight, corrosion resistance, thermal conductivity, electrical isolation, and cost. Calpak USA sources materials from qualified domestic suppliers with full mill certifications and material traceability documentation as required by AS9100 Rev. D and customer specifications.

Yes. Calpak USA regularly produces prototype and low-volume mechanical parts alongside our electronics manufacturing work. Our in-house CNC milling and sheet metal capabilities are well-suited for quantities from one-off prototypes through short production runs of several hundred pieces. Prototype mechanical parts are typically delivered within 1 to 2 weeks depending on complexity, material availability, and finishing requirements. This is particularly valuable for customers who need custom enclosures, heatsinks, brackets, or fixtures to accompany prototype PCB assemblies — Calpak USA can deliver the complete electromechanical assembly from a single source at our Hawthorne, California facility.

Calpak USA offers multiple surface finishing options for fabricated mechanical parts. Standard finishes include deburring, bead blasting, tumbling, anodizing (Type II and Type III hard-coat for aluminum), powder coating, chemical conversion coating (chromate and non-chromate per MIL-DTL-5541), electroless nickel plating, and passivation for stainless steel. Finishing requirements are specified on your engineering drawings and performed to the applicable military or commercial specifications. For finishes that require specialized processing equipment, Calpak USA coordinates with qualified local finishing vendors and manages the complete process including outgoing and incoming inspection to ensure parts meet your dimensional, cosmetic, and performance requirements.

All mechanical fabrication at Calpak USA is performed under our AS9100 Rev. D certified quality management system at our Hawthorne, California facility. Quality controls include first-article inspection (FAI) per AS9102 on new part numbers, in-process dimensional checks using calibrated measuring instruments including calipers, micrometers, height gauges, and pin gauges, final inspection against engineering drawings with documented inspection reports, and material traceability from raw stock through finished part. For critical dimensions, Calpak USA uses coordinate measuring machine (CMM) inspection. Non-conforming parts are segregated and dispositioned through our formal non-conformance process. All inspection records are retained per AS9100 document retention requirements and are available for customer review.