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CNC Milling

For High Quality CNC Parts. Bronze Bearing Prototype. CNC milling machine is also called CNC (Computer Numerical Control) milling machine. In English, it means a milling machine controlled by digital signals with an electronic meter.

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CNC milling machine is a kind of automatic processing equipment developed on the basis of general milling machine, the processing process of both is basically the same, the structure is also somewhat similar. CNC milling machines are divided into two categories: those without tool magazines and those with tool magazines. Among them, the CNC milling machine with tool magazine is also called machining center.

CNC milling is a special form of computer numerically controlled (CNC) machining. Milling itself is a process similar to drilling and cutting, enabling many of the operations of cutting and drilling machines. Like drilling, milling uses a rotating cylindrical cutting tool. However, the tool in a milling machine is able to move along multiple axes and can create a variety of shapes, slots and holes. In addition, the workpiece often moves in different directions through the milling tool, unlike the single-axis motion of a drill.

CNC milling machines are the most widely used type of CNC machine tools. Typically, they are grouped by the number of operating axes, labeled with various letters. x and y indicate horizontal movement of the workpiece (front-to-back and side-to-side in a plane). z represents vertical, or up-and-down, movement, while w represents diagonal movement in a vertical plane. Most machines offer 3 to 5 axes, providing performance along at least the X, Y and Z axes. Advanced machines, such as 5-axis milling centers, require CAM programming for optimal performance due to the incredibly complex geometries involved in the machining process. These machines are extremely useful because they are able to produce shapes that would be nearly impossible using manual tooling methods. Most CNC milling machines also incorporate a device for pumping cutting fluid to the cutting tool during the machining process.

Computer numerically controlled machining centers are used to produce a wide range of parts, and the cost of the tools involved continues to become more affordable. Generally speaking, high volume production requiring relatively simple designs is better served by other methods, although CNC machining can now meet a wide range of manual manufacturing needs. CNC milling centers are the ideal solution for everything from prototyping and short-run production of complex parts to the manufacture of unique pre-finished parts.

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Turning is a form of machining, a material removal process used to create rotating parts by cutting away unwanted material. The turning process requires a lathe or lathe, workpiece, fixture and cutting tool. The workpiece is a pre-formed piece of material that is held in a fixture that is itself attached to the lathe and allows for high speed rotation. The tool is usually a single-point cutting tool that is also secured to the machine, although some operations use a multi-point tool. The cutting tool enters the rotating workpiece and cuts away the metal in small pieces to form the desired shape.

Turning is used to produce rotating, usually male axis symmetrical parts that have many features such as holes, slots, threads, tapers, steps of various diameters, and even contoured surfaces. Parts manufactured entirely by turning typically include a limited number of components, perhaps for prototyping, such as custom-designed shafts and fasteners. Turning is also commonly used as an auxiliary process to add or refine the characteristics of parts made using a different process. Because turning can provide high tolerances and surface finish, it is ideal for adding precision rotating features to parts whose basic shape is already formed. The results show that high efficiency as well as high accuracy can be attained by CNC turning.

Turning is a machining process in which the cutting tool, usually a non-rotating head, describes a spiral tool path by a more or less linear motion while the workpiece rotates. The axis of motion of the tool may really be a straight line, or it may be along some curve or angle, but they are essentially linear (in a non-mathematical sense). Often, the term “turning” is reserved for producing an outer surface by this cutting action, while the same basic cutting action is referred to as “boring” when applied to an inner surface (i.e., a certain type of hole). Thus, the phrase “turning and boring” classifies the larger (and essentially similar) family of processes. Cutting faces on a workpiece (i.e., surfaces perpendicular to the axis of rotation), whether with a turning tool or a boring tool, is referred to as “facing” and can be classified as a subset of both. Today, the most common type of such automation is computerized digital control, better known as CNC. (In turning, a piece of relatively hard material (such as wood, metal, plastic or stone) is rotated and the cutting tool is moved along 1, 2 or 3 axes of motion to produce precise diameters and depths. Turning can be done on the outside of a cylinder or on the inside (also known as boring) to produce tubular parts in a variety of geometries. Although now quite rare, early lathes could even be used to produce complex geometries and even platonic solids; although since the advent of CNC technology, it has become unusual to use non-computerized toolpath control for this purpose. Turning operations are usually performed on lathes, considered to be the oldest machines, and can be of four different types, such as straight, tapered, profiling or external groove turning. These types of turning operations can produce various shapes of materials such as straight, round, curved or slotted workpieces. In general, turning uses simple single point cutting tools. Each group of workpiece materials has an optimal set of tool angles that have evolved over the years. Scrap metal chips from turning operations are known as swarf (North America), or chips (UK). In some areas, they may be referred to as turning.

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Machining centers are developed from CNC milling machines. The biggest difference from CNC milling machines is that the machining center has the ability to automatically exchange machining tools. By installing tools for different purposes on the tool magazine, the machining tools on the spindle can be changed through the automatic tool changer in one clamping to achieve a variety of machining. Function.
CNC machining center is a high-efficiency automatic machine tool composed of mechanical equipment and CNC system suitable for processing complex parts. CNC machining center is one of the most productive and widely used CNC machine tools in the world. Its comprehensive processing ability is strong, the workpiece can complete more processing content after one clamping, and the processing accuracy is high. For batch workpieces with moderate processing difficulty, its efficiency is 5 to 10 times that of ordinary equipment, especially it can complete The processing that many ordinary equipment cannot complete is more suitable for single-piece processing or medium and small batch multi-variety production with complex shapes and high precision requirements. It concentrates the functions of milling, boring, drilling, tapping and thread cutting on one device, so that it has a variety of processing methods. Machining centers are classified according to the spatial position of the spindle during machining: horizontal and vertical machining centers. According to the process and use, there are: boring and milling machining center, compound machining center. According to the special classification of functions, there are: single worktable, double worktable and multi worktable machining center. Machining centers with single, double and triple axes and interchangeable headstocks. According to the classification of guide rails: line rail machining center, hard rail machining center, etc.

Processing principle
Determination of processing route
The CNC lathe feed processing route refers to the path that the turning tool travels from the tool setting point (or the fixed origin of the machine tool) until it returns to this point and ends the processing program, including the cutting processing path and the non-cutting such as cutting in and out of the tool. Empty travel path.
The feed route of finishing is basically carried out sequentially along its part contour, therefore, the focus of the work to determine the feed route is to determine the feed route of rough machining and idle travel.
In CNC lathe processing, the determination of the processing route generally follows the following principles.
①It should be able to ensure the accuracy and surface roughness of the workpiece to be processed.
②Make the processing route the shortest, reduce the idle travel time, and improve the processing efficiency.
③ Try to simplify the workload of numerical calculation and simplify the processing program.
④ For some repetitive programs, subroutines should be used.
Advantages and disadvantages
CNC machining has the following advantages:
① The number of tooling is greatly reduced, and complex tooling is not required to process parts with complex shapes. If you want to change the shape and size of the part, you only need to modify the part processing program, which is suitable for new product development and modification.
②Stable processing quality, high processing precision and high repeatability, which can meet the processing requirements of aircraft.
③ The production efficiency is high in the case of multi-variety and small batch production, which can reduce the time for production preparation, machine tool adjustment and process inspection, and the cutting time is reduced due to the use of the optimal cutting amount.
④ It can process complex profiles that are difficult to process by conventional methods, and even process some unobservable processing parts.
The disadvantage of CNC machining is that the machine tool is expensive and requires a high level of maintenance personnel.

CNC machining center
CNC machining center is a high-efficiency automatic machine tool composed of mechanical equipment and CNC system suitable for processing complex parts. CNC machining center is one of the most productive and widely used CNC machine tools in the world. Its comprehensive processing ability is strong, the workpiece can complete more processing content after one clamping, and the processing accuracy is high. For batch workpieces with moderate processing difficulty, its efficiency is 5 to 10 times that of ordinary equipment, especially it can complete The processing that many ordinary equipment cannot complete is more suitable for single-piece processing or medium and small batch multi-variety production with complex shapes and high precision requirements.
CNC machining center is a kind of CNC machining machine with full functions. It concentrates the functions of milling, boring, drilling, tapping and thread cutting on one equipment, making it have a variety of technological means. The machining center is equipped with a tool magazine, which stores various tools or inspection tools in different quantities, which are automatically selected and replaced by the program during the processing. This is the main difference between it and CNC milling machine and CNC boring machine. Especially for workpieces that must use tooling and special equipment to ensure product quality and efficiency. This will save a lot of time and cost for the development and modification of new products, so that enterprises have strong competitiveness.

Classification of machining centers
Machining centers are often divided into vertical machining centers and horizontal machining centers according to the state of the spindle in space. The spindle of the machining center is in a vertical state in space, called a vertical machining center, and the spindle in a horizontal state in space is called a horizontal machining center. type machining center. The spindle can be converted vertically and horizontally, which is called vertical and horizontal machining center or five-sided machining center, also known as compound machining center. According to the number of machining center columns; there are single-column type and double-column type (gantry type).
According to the number of motion coordinates of the machining center and the number of coordinates controlled at the same time: there are three-axis two-linkage, three-axis three-linkage, four-axis three-linkage, five-axis four-linkage, six-axis five-linkage, etc. Three-axis and four-axis refer to the number of motion coordinates that the machining center has, and linkage refers to the number of coordinates that the control system can control the motion at the same time, so as to realize the position and speed control of the tool relative to the workpiece.
According to the number and function of the workbench: there are single workbench machining center, double workbench machining center, and multi workbench machining center.
According to the machining accuracy: there are ordinary machining centers and high-precision machining centers. Ordinary machining center, the resolution is 1μm, the maximum feed speed is 15 ~ 25m/min, and the positioning accuracy is about 10μm. The high-precision machining center has a resolution of 0.1 μm, a maximum feed rate of 15 to 100 m/min, and a positioning accuracy of about 2 μm. Between 2 ~ 10μm, more than ±5μm, can be called precision grade.

CNC machining center
A CNC machining center is a CNC machine tool with a tool magazine that can automatically change tools and can perform various processing operations on the workpiece within a certain range.
The characteristics of machining parts on the machining center are: after the machined part is clamped once, the CNC system can control the machine tool to automatically select and replace the tool according to different procedures; automatically change the machine tool spindle speed, feed and the movement path of the tool relative to the workpiece And other auxiliary functions, it can continuously and automatically perform multi-process processing such as drilling, countersinking, reaming, boring, tapping, and milling on each processing surface of the workpiece. Since the machining center can complete various processes in a centralized and automatic manner, it avoids human operation errors, reduces workpiece clamping, measurement and adjustment time of machine tools, and workpiece turnover, handling and storage time, greatly improving processing efficiency and machining accuracy. , so it has good economic benefits. Machining centers can be divided into vertical machining centers and horizontal machining centers according to the position of the spindle in space.

CNC method
In CNC machining centers, there are usually two programming methods today: 1. Simple contours – contours composed of straight lines and arcs, which are directly programmed with the G code of the CNC system. ②Complex contour – three-dimensional surface contour, use automatic programming software (CAD/CAM) to draw three-dimensional graphics in the computer, set various corresponding parameters according to the surface type, and automatically generate CNC machining programs. The above two programming methods can basically meet the requirements of CNC machining. However, it is very difficult to process the contour of the function equation curve, because the early CNC system of the milling machine does not have the function operation function, and the processing program of the function equation curve cannot be compiled directly with the G code, and the (lower version) CAD/CAM software usually does not It has the function of inputting graphics directly from equations. Therefore, the method of cutting the curve contour of the function equation is usually: calculate the coordinates of each point on the curve according to the requirements of the drawing, and then use the straight line or arc command code to compile the program according to the calculated coordinate value, and manually enter the system for processing.
The machining center is a high-efficiency and high-precision CNC machine tool. The workpiece can be processed in multiple processes in one clamping. At the same time, it is also equipped with a tool library and has an automatic tool change function. These rich functions of the machining center determine the complexity of the programming of the machining center.
The machining center can realize the linkage control of three or more axes to ensure that the tool can process complex surfaces. In addition to the linear interpolation and arc interpolation functions, the machining center also has various processing canned cycles, automatic tool radius compensation, automatic tool length compensation, graphic display of the processing process, man-machine dialogue, automatic fault diagnosis, offline programming and other functions .
Machining centers are developed from CNC milling machines. The biggest difference from CNC milling machines is that the machining center has the ability to automatically exchange machining tools. By installing tools for different purposes on the tool magazine, the machining tools on the spindle can be changed through the automatic tool changer in one clamping to achieve a variety of machining. Function.
Machining centers can be divided into vertical, horizontal and composite machining centers in appearance. The main shaft of the vertical machining center is perpendicular to the worktable, which is mainly suitable for processing plate and shell workpieces, and can also be used for mold processing. The axis of the main shaft of the horizontal machining center is parallel to the table surface of the worktable. Most of its worktables are CNC rotary tables controlled by servo motors. Box type workpiece processing. The compound machining center mainly refers to that there are two vertical and horizontal spindles on one machining center or the spindle can change the angle by 90°, so that the processing of five surfaces can be realized in one clamping of the workpiece.
Fault 1: The serial encoder of the CNC machining center has a communication error alarm. Reason: The unit detects that the motor encoder of the CNC machining center is disconnected or has poor communication. Check whether the connection between the encoder feedback wire of the motor and the amplifier is correct and firm. If the feedback line is normal, replace the servo motor (because the encoder of the motor is integrated with the motor and cannot be disassembled), if it is an α motor, replace the encoder. If it occurs occasionally, it may be caused by interference. Check whether the shielded wire of the motor feedback wire is in good condition.
Fault 2: The encoder pulse count error alarm of the CNC machining center (LED display 6, the PMM screen of the system displays 303/304/305/308 alarm) Cause analysis: The serial encoder of the servo motor loses pulses during operation, or does not count . Turn off and on again, if there is the same alarm, replace the motor (if it is an α motor, replace the encoder) or feedback cable. If the alarm disappears after the CNC machining center is restarted, it must return to the reference point before running other commands. If the PMM of the system is 308 alarm, it may be caused by interference, turn off and on again.

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CNC PRECISION AUTOMATIC LATHE machine — the full name of the walking CNC lathe, can also be called the spindle box mobile CNC automatic lathe, the economical turning and milling compound machine tool or the slitting lathe. It belongs to precision machining equipment, which can complete compound processing such as turning, milling, drilling, boring, tapping, and engraving at one time. It is mainly used for batch processing of precision hardware and special-shaped non-standard shaft parts.

The CNC PRECISION AUTOMATIC first originated in Germany and Switzerland. In the early stage, it was mainly used for precision machining of military equipment. With the continuous development and expansion of the industrialization process, due to the urgent needs of the market, it was gradually applied to the processing of civilian products;
Compared with CNC lathes, the machine has a qualitative leap in processing efficiency and processing accuracy. Due to the use of dual-axis arrangement of tools, the processing cycle time is greatly reduced. The table overlap function, the thread chip effective axis movement overlap function, and the direct spindle indexing function during secondary machining can shorten the idle time. The chip tool has always been processed in the spindle and the workpiece clamping part, which ensures the constant processing accuracy. This series of machine tools can be equipped with an automatic feeding device to realize fully automatic production of a single machine tool and reduce labor costs and product defect rates. It is very suitable for mass production of precision shaft parts.

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Compared with the conventional CNC machining process, the outstanding advantages of composite machining are mainly reflected in the following aspects:
(1) Shorten the product manufacturing process chain and improve production efficiency. Turn-milling composite machining can realize all or most of the machining processes in one loading, thus greatly shortening the product manufacturing process chain. In this way, on the one hand, the production auxiliary time caused by the change of the loading card is reduced, and at the same time, the manufacturing cycle and waiting time of the tooling and fixture are also reduced, which can significantly improve the production efficiency.
(2) Reduce the number of clamping and improve the machining accuracy. The reduction in the number of card loadings avoids the accumulation of errors due to positioning fiducial conversions. At the same time, most of the turning-milling composite processing equipment has the function of online detection, which can realize the in-situ detection and precision control of key data in the manufacturing process, thereby improving the processing precision of products.
(3) Reduce the floor space and reduce the production cost. Although the price of a single turn-milling compound processing equipment is relatively high, due to the shortening of the manufacturing process chain and the reduction of equipment required for the product, as well as the reduction of the number of fixtures, workshop area and equipment maintenance costs, it can effectively reduce the overall fixed assets. The cost of investment, production operation and management.

CNC PRECISION AUTOMATIC Design Features Edit Broadcast
Since the structure of the centering machine is different from that of the traditional CNC lathe, the processing efficiency and processing accuracy of the centering machine are higher than those of the CNC lathe. The machine adopts two-axis arrangement of tools. This design greatly saves the processing cycle time. By shortening the tool exchange time between the arrangement of tools and the opposite tool table, the overlapping functions of multiple tool tables and effective axis movement of thread chips are realized. , The direct spindle indexing function during the secondary processing shortens the actual idle time.
In the machining process of the spindle and the workpiece clamping part, the chip tool has always played a very important role, which provides a strong guarantee for constant machining accuracy. As far as the centering machine market is concerned, 38mm is its maximum processing diameter, which makes the centering machine have a great advantage in the precision shaft processing market. This series of machine tools can also be equipped with an automatic feeding device to realize fully automatic production of a single machine tool, reducing labor costs and defective products in the production process, and can be used to produce large quantities of precision shaft parts.

CNC machine tool is the abbreviation of Computer numerical control machine tools, which is an automatic machine tool equipped with a program control system. The control system can logically process the program specified by the control code or other symbolic instructions, decode it, represent it with coded numbers, and input it into the numerical control device through the information carrier. After arithmetic processing, various control signals are sent by the numerical control device to control the action of the machine tool, and the parts are automatically processed according to the shape and size required by the drawing.
CNC machine tools can better solve the problem of complex, precise, small batch, and multi-variety parts processing. It is a flexible and high-efficiency automatic machine tool, which represents the development direction of modern machine tool control technology. chemical products.

Computer numerical control machine tools
main feature
CNC machine

The operation and monitoring of CNC machine tools are all completed in this CNC unit, which is the brain of CNC machine tools. Compared with ordinary machine tools, CNC machine tools have the following characteristics:
1. It has strong adaptability to processing objects, adapts to the characteristics of single-piece production of molds and other products, and provides suitable processing methods for mold manufacturing;
2. High processing precision and stable processing quality;
3. Multi-coordinate linkage can be carried out, and parts with complex shapes can be processed;
4. When the machining parts are changed, generally only the CNC program needs to be changed, which can save production preparation time;
5. The machine tool itself has high precision and high rigidity, and can choose favorable processing amount, and the productivity is high (generally 3 to 5 times that of ordinary machine tools);
6. The machine tool has a high degree of automation, which can reduce labor intensity;
7. Conducive to the modernization of production management. CNC machine tools use digital information and standard codes to process and transmit information, and use computer control methods, which lays the foundation for the integration of computer-aided design, manufacturing and management;
8. Higher quality requirements for operators and higher technical requirements for maintenance personnel;
9. High reliability.
Compared with traditional machine tools, CNC machine tools have the following characteristics.
1. Highly flexible
CNC machine tool (Fig. 2)
CNC machine tool (Fig. 2)
Machining parts on CNC machine tools mainly depends on the processing program. It is different from ordinary machine tools. It does not need to be manufactured, replace many molds and fixtures, and does not need to readjust the machine tool frequently. Therefore, CNC machine tools are suitable for occasions where the processed parts are frequently replaced, that is, suitable for the production of single-piece, small-batch products and the development of new products, thereby shortening the production preparation cycle and saving a lot of process equipment costs.
2. High machining accuracy
The machining accuracy of CNC machine tools can generally reach 0.05-0.1mm. The CNC machine tools are controlled in the form of digital signals. Each time the CNC device outputs a pulse signal, the moving parts of the machine tool move by a pulse equivalent (usually 0.001mm), and the machine tool advances. The average error of the backlash to the transmission chain and the screw pitch can be compensated by the numerical control device, so the positioning accuracy of the numerical control machine tool is relatively high.
3. Stable and reliable processing quality
Machining the same batch of parts, on the same machine tool, under the same processing conditions, using the same tool and processing program, the tool travel path is exactly the same, the consistency of the parts is good, and the quality is stable.
4. High productivity
Five-axis linkage machining center
Five-axis linkage machining center
The CNC machine tool can effectively reduce the processing time and auxiliary time of the parts. The CNC machine tool has a large range of spindle sound speed and feed rate, allowing the machine tool to perform powerful cutting with a large amount of cutting. CNC machine tools are entering the era of high-speed machining. The rapid movement and positioning of moving parts of CNC machine tools and high-speed cutting have greatly improved productivity. In addition, when used in conjunction with the tool magazine of the machining center, it can realize continuous processing of multiple processes on one machine tool, reduce the turnaround time between processes of semi-finished products, and improve productivity.
5. Improve working conditions
Before the CNC machine tool is adjusted, the program is input and started, and the machine tool can automatically and continuously process until the end of the process. All the operator has to do is input the program, load and unload parts, prepare the tool, observe the processing state, inspect the parts, etc. The labor intensity is greatly reduced, and the labor of the machine tool operator tends to be intellectual work. In addition, machine tools are generally combined, which is both clean and safe.
6. Utilize production management modernization
The processing of CNC machine tools can accurately estimate the processing time in advance, standardize and modernize the tools and fixtures used, and easily realize the standardization of processing information. It has been organically combined with computer-aided design and manufacturing (CAD/CAM), It is the basis of modern integrated manufacturing technology


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