CNC machining produces smartphone housings from solid aluminum billets with micron-level tolerances, eliminating weak points inherent in multi-piece assemblies. The one-piece machined aluminum housing resists bending and impact better than plastic or die-cast shells, and precision milling achieves consistent surface flatness. Subsequent finishing operations—such as sandblasting, polishing, and anodizing—yield scratch-resistant, high-gloss or matte surfaces that retain their appearance under heavy use.

Advanced 5-axis CNC milling and micro-turning deliver the complex geometries and tight tolerances (down to ±0.01 mm) required for headphone drivers, housings, and wearable sensor enclosures. Multi-axis machining allows undercut features and internal cavities without secondary jigging, while precision turning on Swiss-type CNC lathes produces small, cylindrical components (e.g., earbud nozzles) with smooth bores and consistent wall thickness.

CNC rapid prototyping converts CAD designs into physical prototypes in days rather than weeks. CAM software automatically generates toolpaths for roughing, semi-finishing, and finishing in one setup, eliminating manual mold tooling. Designers can iterate directly on metal or engineering-grade plastics, test fit and function, then update the CAD model—all without the lead times of injection molding or die casting. This end-to-end process typically reduces prototype turnaround by 50–70%.

For medium-volume runs (hundreds to thousands of units), CNC machining avoids the upfront tooling costs of stamping or casting. Automated tool changing and nesting optimize material usage, reducing scrap by up to 30%. High spindle speeds and advanced tool coatings minimize cycle times, lowering per-part labor costs. Lifecycle analyses show CNC-machined metal parts often outperform plastic–injection counterparts in durability, reducing warranty and replacement expenses over time.

Anodizing with micropore sealing: Hard-coat anodizing fills surface porosity and creates a diffuse, matte finish that resists fingerprints and wear.
Physical Vapor Deposition (PVD) coatings: Ultra-thin DLC (diamond-like carbon) or TiN (titanium nitride) films add hydrophobic barriers that shed oils and enhance scratch resistance.
Plasma polymer anti-static treatment: A post-machining plasma deposition applies a nanolayer of anti-static polymer, preventing charge buildup on metal housings used in smart home sensors and portable electronics.