Aerospace Casting Replaced with Hog‑Out
A large aerospace OEM was struggling with casting delivery and quality. Mac Machine provided the solution: machine this complex component complete from solid billet, fully inspected, and delivered as one accountable package.
The engagement
From problem casting to finished part.
01 / CHALLENGE
Casting supply at risk
The OEM's casting source was struggling on both delivery and quality — putting the program schedule at risk for a complex aerospace component.
02 / SOLUTION
Hog-out from solid billet
We replaced the casting entirely, machining the full geometry from solid billet on our CNC machining centers — removing the foundry from the supply chain.
03 / RESULT
One accountable package
A single source for the finished part: machined, fully inspected, and delivered complete. The component is now in production.
Process route
Billet to delivery under one roof.
OP 10
DFM review
Casting geometry evaluated and adapted for machining from billet.
OP 20
Programming
Toolpaths built and verified in CAM before any metal is cut.
OP 30
Machining
Full geometry machined from solid billet.
OP 40
Full inspection
Every part inspected against print, with documentation.
OP 50
Delivery
Finished, traceable components shipped as one package.
Why hog-out
Casting vs. machined from billet.
| Factor | Casting route | Hog-out route |
|---|---|---|
| Supply chain | Foundry, then a separate machine shop | One shop, one point of accountability |
| Tooling | Patterns and molds to build and maintain | No foundry tooling — program changes are CAM changes |
| Material | Cast structure, with porosity and inclusion risk | Wrought billet with consistent, certified properties |
| Schedule | Dependent on foundry capacity and yield | Controlled in-house from raw material to shipment |
| Inspection | Split between foundry and machinist | Full inspection of the finished part |
Customer, program, and part details are withheld to protect confidentiality. Additional information is available on request.
Have a casting that's holding up your program?
Send the drawing — we'll tell you whether a hog-out makes sense.