A long time ago I remember having a problem with a young trainee engineer who was very proud of his work even though it had a big problem. The problem was the design had square holes. This made sense as he wanted to utilize square steel bar that would mate into the square holes. The problem was not just the stress concentration in the corners but we had no way to make the part. Using normal machine tools the part was impossible to make, there was no broaching tools available or EDM.
Now that same engineer has a choice. Dijet Industrial Co Ltd of Japan have worked out how to machine the perfect square. I'm not sure if this is a serious application or just a company pushing the boundaries of knowledge in wanting to know what it could achieve.
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