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Advantages of CNC Machining Prototypes
In case you were wondering if to choose alternative CNC rapid prototyping, here are some advantages to consider:
Cost Effectiveness
This rapid prototype manufacturing process helps you to save costs by rectifying any defects and errors that may occur in a small prototype batch. It doesn’t wait until the final production stage to correct such defects. In addition, you can make future modifications to the CAD files if needed instead of creating a new design from scratch.
Repeatability and Consistency
The CNC prototype machining has a high degree of repeatability compared to alternative prototype processes. For this reason, all finished product manufactured using the CNC machining process maintains similar features.
CNC precision machining has the ability to consistently create identical products, making it the ideal prototyping process. Prototypes imitate the original designs, and CNC machining prototype offers the necessary precision.
Time Saving Process
CNC machining prototypes do not require mold creation or any time-consuming set-up. As a result, it helps to fast-track the process. Additionally, the approach is flexible as you can modify CAM/CAD files allowing the machining centers to alter the prototype’s specifications and take it through the CNC machining again without delay.
High Precision
CNC machines offer dimensional accuracy and tighter tolerances regardless of the material due to increased control over the cutting tools’ movement. High precision is one of the essential elements of prototypes that makes them suitable for the intended purpose.
A CNC machine can produce tolerances up to ±0.05mm, which is accurate enough for most commercial applications. However, you may need a specialized cutting tool for automotive and aerospace industries requiring tighter tolerances. Also, the CNC machining process has improved accuracy, which helps manufacturers identify defects in the machined prototypes due to errors in the product design.
Material Versatility
CNC prototype machining is compatible with different highly machinable material options, unlike other processes. These CNC machining materials often range from the hardest/strongest metals and alloys to materials like plastics and wood. Hence, you can use the material for your final product for your CNC prototyping process.
For instance, there are limited methods for sheet metal forming. Consequently, CNC machining is an excellent choice for developing metal prototypes that require greater mechanical stability. Likewise, CNC machining is ideal for different prototypes with distinct mechanical properties. All you have to do is make minimal adjustments to the feed and speed of the cutting tool.
Here are some material options perfect for CNC prototype machining:
- Polycarbonate (PC)
- Polyoxymethylene (POM)
- Polypropylene (PP)
- Low-Density Polyethylene (LDPE)
- High-Density Polyethylene (HDPE)
- Aluminum
- Zinc
- Brass
- Copper
- Bronze
- Titanium
- Stainless steel
- ABS
- Magnesium
Disadvantages of Prototype CNC Machining
Although Prototype CNC machining offers enormous advantages, it has its limitations. Here are some of them:
Environmentally Unfriendly
The Prototype CNC machining is a subtractive manufacturing technique that makes it a waste generator. Generally, it removes a large portion of the workpiece/material to create the desired part. However, most removed material becomes chipped plastics and metal, unfit for other uses. Hence, you will have to dispose of the chipped material.
Additionally, you incur higher material costs when using prototype CNC machining techniques because of the increased material usage and waste. Nevertheless, you can choose to recycle the chipped material to avoid the severe environmental impact of the process.
Cost More than 3D Printing
CNC prototype machining may cost more for certain startups compared to 3D printouts, which require less personnel supervision and power supply. Additionally, CNC prototype machining has higher material costs in contrast to the printing material used by the 3D printer, such as PLP and PLA. Although PLA is cheaper, its other characteristics don’t fit most prototyping requirements.
This factor is one of the reasons why product designers may go for alternative prototyping methods even if they plan CNC machining for their final products. However, it would help to note that the added expense of the CNC prototype machining comes with material versatility and greater accuracy.
Geometrical Restrictions
Since CNC machines work from the outside, it will be nearly impossible to machine specific geometries such as internal components using this process. In contrast, additive manufacturing processes work from the inside out. Hence, they can manufacture different internal geometries.
Applications of CNC Machined Prototypes
CNC machined prototypes have applications in nearly all industries that need precision machining. These industries often require functional prototypes with identical features to the final product.
Here are some of the industries that take advantage of CNC machining prototypes:
Automotive Industry
CNC prototype machining is the ideal process for designing prototypes for the automotive sector. The automotive industry uses components like gears and others with extremely high tolerances. Prototype CNC machining allows automakers to create prototypes to exact specifications and test these parts to see if they fit the intended purpose.
Aerospace Industry
The aerospace industry is a sector that doesn’t allow errors in machining its parts. As a result, it consistently goes through rapid prototyping to test the functionality of the innovations in materials and components. This allows manufacturers to test the functionality of prototypes before using them in aircraft. Examples of CNC machined prototypes in the aerospace industry include airfoils, landing gear ports, bushings, etc.
Medical Industry
The medicine sector continues to evolve rapidly, with new medical devices and prosthetics providing new possibilities for treatments. The CNC manufacturing process helps manufacturers identify and rectify machined parts’ errors since it deals with life. Machined prototypes in the medical sector include implants, orthotic devices, MRI machines, etc.
Military and Defense
CNC prototyping services have ushered in a massive breakthrough in the military and defense sectors. CNC parts in this sector are made of hard metals; as a result, it requires the highest precision. Prototype CNC machining is a go-to choice for creating new weapons, warfare vehicles, and other components.
Tips For Preparing Quality CAD Models For Prototype CNC Machining Process
The quality of your CNC machined prototypes can vary based on the CAD file you use. These CAD files convey visual information, providing critical dimensions for the machined parts. Consequently, CNC prototypes that require superior quality rely on a high-quality CAD design. Here are tips on how to achieve quality CAD models:
Choosing the Right CAD Software
Several industries use different CAD software for custom prototyping. However, some are simple and reliable, while others can be complicated or unsuitable for some applications. As a result, it is essential to choose the right CAD software that suits your application or prototype needs.
Ideal Wall Thickness
When making your design, you should try as much to avoid thin wall thickness as it can reduce the mechanical stability of CNC custom prototypes and exhibit weakness. A good rule of thumb is to maintain metal walls greater than 0.8 mm. however, the thickness for plastic walls should be greater than 1.5 mm.
Optimizing Design Elements
It is essential to optimize the design elements like cavities and holes when using CNC machines. For example, the maximum depth achieved in the case of end milling is thrice the diameter of the tool. So, identify and limit the dimensions of such cavities or holes.
Simplify Drawings
There are different ways of creating CAD designs for a particular prototype. However, keeping the drawing as simple as possible helps to prevent unnecessary machining procedures. More importantly, it is best to divide the drawing into two aspects/parts that can be joined later when dealing with complex CNC machining.
Creating a Checklist
Creating an initial checklist of the designs and qualities you want in the prototypes is very important. It is easier to add features while designing the CAD file than trying to change the file later.
AT-Machining: The Precision & Rapid Prototype CNC Machining Service For You
AT-Machining is the ideal one-stop CNC machine shop capable of bringing your CAD blueprint to life with the best results. We offer a reliable CNC machining service with our advanced technology and vast engineering experience. We have 3, 4, and 5-axis CNC machines that help to deliver the highest accuracy, precision, and reliability, producing high-quality precision prototypes for various industries.
We ensure design optimization and budget maximization that allows us to provide cost-effective CNC prototyping services. Ready to kick-start your CNC prototype machining? Contact us, and let’s get started.
Conclusion
Prototype CNC machining is a reliable solution for manufacturing small volumes of high-quality prototypes due to its high precision and faster cycle times. Engineers often adopt CNC prototype machining because it allows them to test the functionality of CNC parts before proceeding to large-volume production. However, you need adequate knowledge of the process to get the best results.
