Abstract: A method and an apparatus for machining an exterior surface of a metal alloy casing of a portable electronic device to form a combination of a flat edge surface, a curved edge surface and a flat bottom surface is disclosed. The flat edge surface is abraded by contacting a first flat section of a rotating cutting tool along a first circuit of a pre-determined continuous spiral path. The curved edge surface is abraded by contacting a convex section of the rotating cutting tool along additional circuits of the first pre-determined continuous spiral path. The pitch of vertical movement of the cutting tool is adjusted for each circuit of the continuous spiral path based on a resulting curvature of the metal alloy casing. The bottom surface is abraded by contacting a flat section of the cutting tool along a second pre-determined alternating direction linear path.

Abstract: Methods and structures for manufacturing and assembling matching parts in a manufacturing line are described. In some embodiments, the parts are portions of a consumer product, such as an electronic device. The matching parts are manufactured and assembled in a way such that the interface between the matching parts is substantially seamless. In some embodiments, the interface has a feature with curved portions. Methods involve measuring the dimensions of a primary part and custom machining a secondary part to seamlessly fit with the primary part. In this way, the secondary part is made to uniquely fit the primary part. The primary and secondary parts can be marked to identify them as matching parts in a manufacturing environment where numerous pairs of parts are made.

Abstract: Methods and structures for manufacturing and assembling matching parts in a manufacturing line are described. In some embodiments, the parts are portions of a consumer product, such as an electronic device. The matching parts are manufactured and assembled in a way such that the interface between the matching parts is substantially seamless. In some embodiments, the interface has a feature with curved portions. Methods involve measuring the dimensions of a primary part and custom machining a secondary part to seamlessly fit with the primary part. In this way, the secondary part is made to uniquely fit the primary part. The primary and secondary parts can be marked to identify them as matching parts in a manufacturing environment where numerous pairs of parts are made.

Abstract: A method and an apparatus for machining an exterior surface of a metal alloy casing of a portable electronic device to form a combination of a flat edge surface, a curved edge surface and a flat bottom surface is disclosed. The flat edge surface is abraded by contacting a first flat section of a rotating cutting tool along a first circuit of a pre-determined continuous spiral path. The curved edge surface is abraded by contacting a convex section of the rotating cutting tool along additional circuits of the first pre-determined continuous spiral path. The pitch of vertical movement of the cutting tool is adjusted for each circuit of the continuous spiral path based on a resulting curvature of the metal alloy casing. The bottom surface is abraded by contacting a flat section of the cutting tool along a second pre-determined alternating direction linear path.