An automotive modification workshop contacted us to manufacture a custom intake manifold from 6061-T6 billet aluminum. After reviewing the customer’s design drawings, we identified the primary technical requirements: internal surface smoothness, hole positional accuracy, and overall structural strength.

To meet these specifications, we utilized 5-axis CNC machining instead of traditional 3-axis methods. The 5-axis process required fewer setups (clamping operations), which not only shortened production time but also minimized cumulative errors caused by repeated positioning. During the machining process, we focused on the surface finish of the internal air passages to optimize airflow. Real-time dimensional inspections were conducted at each stage to ensure that all parameters remained within the tolerances specified in the drawings.

Part type: Custom Billet CNC Intake Manifold

Material: Aluminum 6061-T6

Quantity: 2 pcs

Lead Time: 7 day

Material Density & Structural Integrity

• Cast: Castings can suffer from internal porosity (tiny air bubbles trapped during cooling). Under high boost pressure (30+ PSI), these weak points can lead to catastrophic failure or “boost leaks.”
• Billet CNC: Our manifold is carved from a solid block of 6061-T6 aerospace-grade aluminum. The grain structure remains uniform and dense, offering significantly higher tensile strength and the ability to withstand extreme pressures without deformation.

Airflow Precision & Surface Finish

• Cast: The interior of cast runners is often rough and inconsistent due to the sand-casting process. This creates turbulent air, which reduces engine efficiency.
• Billet CNC: With our 5-axis CNC milling, we achieve a mirror-smooth internal surface (Ra 0.8 or better). Every runner is identical to the micron, ensuring perfectly balanced airflow to all cylinders for maximum combustion efficiency.

Wall Thickness & Weight Optimization

• Cast: To compensate for material weakness, cast parts are often over-engineered with thick, heavy walls, adding unnecessary weight to the front of the car.
• Billet CNC: CNC allows us to machine thinner yet stronger walls and complex geometries that are impossible to achieve with a mold. This results in a part that is both lighter and more durable.

Zero Tooling Costs & Rapid Iteration

• Cast: Requires expensive and time-consuming molds (Tooling), making custom designs or small batches prohibitively expensive.
• Billet CNC: We go directly from CAD to CAM. This allows for 100% custom port matching to your specific cylinder head without the need for a $10,000 mold, making it ideal for professional racing teams and bespoke builds.

We provide custom CNC machining services for custom automotive parts to meet different vehicle models and usage needs. Relying on 5-axis machining technology, we accurately reproduce drawing requirements and solve various special adaptation and precision needs.

We provide custom CNC machining services for low-volume production and Rapid Prototyping for design verification.  Click Here to Upload Your CAD Files