Custom CNC Machined Aluminum 6061 Brake Lever

This custom brake lever is manufactured from Aluminum 6061 using 3-axis CNC milling, with a specified dimensional tolerance of ±0.01 mm.

The component features an elongated profile with multiple machined cutouts, a splined bore, and a split-end geometry. These distinctive features combine an open structural design with detailed machined profiles.

The finished parts are shown in several colors, including blue, black, purple, and red, demonstrating the different appearances achievable through colored anodizing.

Lightweight Cutout Design

The brake lever incorporates three prominent openings along its elongated body. These cutouts remove material from the main profile while retaining the surrounding structural sections.

Their varying shapes, internal corners, and machined edges distinguish the component from a conventional solid lever design.

Splined Bore and Split-End Geometry

One end of the component features an internally splined opening connected to a split section.

This geometry introduces additional machining features beyond the external profile and cutouts. The internal tooth-like profile and adjacent split require consideration of feature accessibility and dimensional requirements during manufacturing.

Detailed Milled Profiles

The component includes multiple recessed regions, contoured edges, and transitions between solid sections and open cutouts.

Three-axis CNC milling is used to manufacture the part according to the supplied geometry and dimensional specifications.

Multiple Anodized Colors

The brake levers are presented in blue, black, purple, and red anodized finishes.

Color anodizing provides decorative color options for aluminum components while forming an anodic oxide layer on the treated surface. The finished appearance depends on the selected color and surface preparation requirements.

The different color variants retain the same general component design shown in the photographs.

3-Axis CNC Milling

The brake lever is manufactured using 3-axis CNC milling.

The milling operations produce the elongated external profile, internal openings, recessed features, and other accessible machined surfaces required by the component design.

The splined bore and split-end geometry are additional features that must be considered when planning the machining operations.

The exact machining sequence, cutting tools, and workholding arrangement are not specified in this case.

Color Anodizing

Following the machining stage, the component receives a colored anodized finish.

The photographs show several finished color variants, demonstrating how the same machined component design can be supplied with different external appearances.

Color selection and finish requirements are determined according to the customer's specifications.

Several geometric features are relevant when evaluating the manufacturability of this component.

Internal Cutouts and Edge Geometry

The elongated openings introduce internal contours and transitions that must be considered when selecting machining strategies. Tool accessibility and the specified edge geometry influence how these features can be produced.

Splined Opening

The internally splined feature has a different geometry from a conventional circular bore. Its profile and dimensional requirements need to be reviewed against the engineering drawing when determining the appropriate manufacturing approach.

Dimensional Requirements

The specified tolerance for this component is ±0.01 mm. Actual inspection requirements and acceptance criteria are determined by the customer drawing and applicable specifications.

Surface Finish Requirements

Colored anodizing introduces an additional finishing stage after machining. Surface appearance, color requirements, and any dimensionally sensitive features should be considered when specifying the final finish.

T-One provides custom CNC milling services for aluminum components with detailed profiles, machined openings, and specified dimensional requirements.

Our manufacturing services support drawing-based production with material selection, machining, surface finishing, and inspection options based on project requirements.

For similar custom aluminum components, submit your engineering drawings, required quantities, and technical specifications for manufacturing evaluation and quotation.