Material Selection: 6061-T6 is a reasonable choice for specific scenarios compared to 7075-T6 (high strength) or ADC12 (casting suitability).

Cutting Tools and Parameters: 

Diamond coated cutting tools are used to optimize cutting parameters (such as spindle speed of 8000-12000 rpm, feed rate of 0.05-0.1mm/tooth), reducing the impact of tool wear on accuracy.

Clamping: Use vacuum fixtures or low stress flexible fixtures to reduce the risk of thin-walled deformation.

Surface Treatment and Size Compensation:Anodizing compensation

Reserve an oxide layer thickness (about 0.02mm) for key mating surfaces, or use local masking (such as acid resistant tape) to protect high-precision areas.

Sealing treatment: After anodizing, it is sealed with boiling water or nickel salt to enhance corrosion resistance.

Testing: Perform blue light 3D scanning on the first batch of workpieces to generate a full-size report.