<p data-pm-slice="1 1 []" id="isPasted">When a leading INDEX multi-spindle machine encountered significant challenges with chip removal, tool life, and coolant management, the introduction of a custom 3D-printed coolant ring provided an innovative solution that dramatically improved performance.</p><p data-pm-slice="1 1 []" id="isPasted"><strong>The Challenge: Poor Chip Removal and Inconsistent Coolant Coverage</strong></p><p>The machining process on an <a href="https://www.index-group.com/en_us/company/about-us/index-corporation" target="_blank" rel="noopener noreferrer">INDEX</a> multi-spindle machine was being compromised by poor chip removal, leading to shortened tool life and heightened fire risks. These issues stemmed from inconsistent coolant coverage, which was exacerbated by the machine’s compact design. Standard coolant nozzles were difficult to install due to limited space, and accessing tools with the probe was challenging. Moreover, operators were required to manually remove coolant lines during each tool change, introducing delays and variability that depended on the skill and experience of the operator.</p><p>This situation not only reduced the efficiency of the machining process but also posed safety risks, making it clear that a more reliable and effective solution was needed.</p><p><br></p><p><strong>The Solution: A Custom Metal 3D-Printed Coolant Ring</strong></p><p>To address these challenges, the engineering team designed a custom metal 3D-printed coolant ring with internal channels optimized for efficient coolant flow. <a href="https://oneclickmetal.com/boldseries/" target="_blank" rel="noopener noreferrer">Metal 3D printing</a> was chosen for its ability to produce highly customized parts that precisely meet the stringent specifications required for this application.</p><p>The coolant ring was engineered to withstand coolant pressures of up to 40 bar, resist oil, and ensure non-flammability. It was fabricated from non-toxic, non-corrosive materials to maintain an absence of contaminants throughout its life cycle. The design also ensured that the coolant ring was easy to install, space-saving, and allowed for easy probe accessibility.</p><p>The coolant oil is directed through an adapter block into the inlet of the coolant ring. Inside the ring, the oil flows uniformly, being dispensed evenly from three openings to ensure precise delivery to the tool's tip. This design not only improved coolant coverage but also enhanced process stability, as the coolant ring could be removed and reattached independently of the operator, significantly reducing the time required for tool changes.</p><p><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1730200060177-Coolant+ring.jpg" style="width: 487px;" class="fr-fic fr-dib"></p><p><strong>The Benefits: Enhanced Efficiency, Safety, and Tool Life</strong></p><p>The introduction of the custom 3D-printed coolant ring brought numerous benefits to the machining process:</p><ol><li data-list-indent="1" data-list-type="bulleted"><p><strong>Better Chip Removal</strong>: The optimized design of the coolant ring ensured consistent and effective coolant flow, greatly improving chip removal and reducing the risk of tool damage.</p></li><li data-list-indent="1" data-list-type="bulleted"><p><strong>Increased Tool Life by a Factor of 20</strong>: With improved coolant coverage and chip removal, the tool life was extended dramatically, reducing the frequency of tool changes and lowering operating costs.</p></li><li data-list-indent="1" data-list-type="bulleted"><p><strong>Improved Process Stability</strong>: The ability to remove and reattach the coolant ring without relying on the operator reduced variability and enhanced overall process stability.</p></li><li data-list-indent="1" data-list-type="bulleted"><p><strong>Three Times Faster Tool Change Time</strong>: The streamlined design and ease of reattachment allowed for much quicker tool changes, tripling the speed of this critical process and further enhancing productivity.</p></li><li data-list-indent="1" data-list-type="bulleted"><p><strong>Safer Manufacturing Environment</strong>: The consistent coolant coverage and improved chip removal minimized the risk of fire, contributing to a safer working environment.</p></li></ol><p><strong>Conclusion: A Custom Solution for Optimized Performance</strong></p><p>The integration of a custom metal 3D-printed coolant ring into the INDEX multi-spindle machine represents a significant advancement in machining efficiency and safety. By leveraging the capabilities of metal 3D printing, the engineering team was able to overcome the limitations of traditional coolant systems, providing a solution that not only met but exceeded the demands of the application. This case study highlights the transformative potential of 3D printing in creating tailored solutions that enhance the performance and reliability of critical manufacturing processes.</p>

In the world of precision machining, efficiency and reliability are paramount. This case study explores the challenge, solution, and benefits of integrating a metal 3D-printed coolant ring into the machining process.

Improving Efficiency with Customized 3D-Printed Coolant Rings

<p data-pm-slice="1 1 []" id="isPasted">The potential of metal 3D printing has long extended beyond prototyping, moving into the realm of serial production. In a compelling case study, INDEX-Werke demonstrates how this innovative technology can optimize production efficiency, reduce costs, and improve overall quality. By shifting key components of its multi-spindle automatic machines from conventional manufacturing to metal additive manufacturing, INDEX proves that metal 3D printing is not only feasible for serial production but also highly advantageous.</p><p><strong>The Challenge: Complex Assembly and High Costs</strong></p><p>INDEX's multi-spindle automatic machines require a bar feeder to guide raw material into the processing chamber. This process involves a slider, composed of a <strong>slider trolley</strong> and a <strong>clamping piece</strong>. Traditionally, the production of these components was complex, involving numerous steps such as welding and assembly, which led to higher costs and increased lead times.</p><p><span class="fr-img-caption fr-fic fr-dib" style="width: 567px;"><span class="fr-img-wrap"><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzI3Nzc4Mjg5NjIxLUluZGV4IHRlaWxlIGtvbnZlbnRpb25lbGwuanBnIiwiZWRpdHMiOnsicmVzaXplIjp7IndpZHRoIjo5NTAsImZpdCI6ImNvdmVyIn19fQ==" style="width: 567px;" class="fr-fic fr-dib" alt="Conventional manufactured slider trolley and clamping piece"><span class="fr-inner">Conventional manufactured slider trolley and clamping piece</span></span></span></p><p>For example, the slider trolley was produced by welding a turned part to a base plate, a process prone to errors, especially with the weld seams. The clamping piece, on the other hand, required multiple parts to be assembled from different suppliers, further complicating the supply chain and leading to significant assembly times.</p><p><strong>The Solution: Transition to Metal 3D Printing</strong></p><p>INDEX leveraged <strong>Laser Powder Bed Fusion (LPBF)</strong> technology for the additive manufacturing of these components. By redesigning the slider trolley and clamping piece for 3D printing, the company eliminated the need for multiple parts and welding, allowing each component to be manufactured in one piece.</p><p><span class="fr-img-caption fr-fic fr-dib" style="width: 439px;"><span class="fr-img-wrap"><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzI3Nzc4MzczMjg3LVNjaGllYmVyd2FnZW4gb3B0aW1pZXJ0LW1pbi5qcGciLCJlZGl0cyI6eyJyZXNpemUiOnsid2lkdGgiOjk1MCwiZml0IjoiY292ZXIifX19" style="width: 437px;" class="fr-fic fr-dib"><span class="fr-inner">Metal 3D printed slider trolley</span></span></span></p><p><span class="fr-img-caption fr-fic fr-dib" style="width: 435px;"><span class="fr-img-wrap"><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzI3Nzc4NTMwMDQ5LTQuanBnIiwiZWRpdHMiOnsicmVzaXplIjp7IndpZHRoIjo5NTAsImZpdCI6ImNvdmVyIn19fQ==" style="width: 433px;" class="fr-fic fr-dib"><span class="fr-inner">Metal 3D printed clamping piece</span></span></span>The use of <a href="https://oneclickmetal.com/powder-management/" target="_blank" rel="noopener noreferrer"><strong>1.2709 steel</strong></a> in combination with a <a href="https://oneclickmetal.com/boldseries-technical-specifications/" target="_blank" rel="noopener noreferrer"><strong>200W fiber laser</strong></a> enabled the production of highly durable parts capable of withstanding mechanical and thermal loads, essential for reliable operation within the machine’s high-stress environment. This transition to 3D printing brought significant improvements, particularly in terms of assembly and overall manufacturing efficiency.</p><p><strong>Key Benefits of Metal 3D Printing for Serial Production</strong></p><ol><li data-list-indent="1" data-list-type="numbered"><p><strong>Reduced Lead Times</strong>: One of the most significant advantages of metal AM for serial production is the dramatic reduction in lead times. For example, the printing time for 42 slider trolleys was reduced from <strong>74.5 hours</strong> to&nbsp;<strong>50.5 hours</strong> due to design optimization. Similarly, the clamping piece, which used to require extensive assembly, could now be produced in a single piece, cutting total lead time from 42 days (traditional method) to just 10 days with 3D printing.<br><br></p></li><li data-list-indent="1" data-list-type="numbered"><p><strong>Cost Savings</strong>: The shift to metal 3D printing resulted in a substantial reduction in costs. The manufacturing cost per slider trolley dropped from <strong>€127</strong> to <strong>€29</strong>, while the cost per clamping piece was reduced from <strong>€205</strong>to&nbsp;<strong>€97</strong>. These cost savings stem from eliminating welding and assembly steps, reducing material waste, and optimizing the design for additive manufacturing.<br><br></p></li><li data-list-indent="1" data-list-type="numbered"><p><strong>Optimized Material Use</strong>: By further adapting the design to fit the capabilities of 3D printing, INDEX was able to reduce material consumption. For example, material usage for a build plate full of slider trolley was reduced from <strong>457 cm³</strong> to&nbsp;<strong>381 cm³</strong>, minimizing waste and further decreasing production time.<br><br></p></li><li data-list-indent="1" data-list-type="numbered"><p><strong>Enhanced Design Flexibility</strong>: Metal 3D printing offers unprecedented design freedom, allowing INDEX to create components that would have been impossible or highly inefficient to manufacture using conventional methods. The clamping piece, for instance, no longer required multiple parts and could be produced with pre-printed threads, further simplifying the manufacturing process.<br><br></p></li><li data-list-indent="1" data-list-type="numbered"><p><strong>Reduced Scrap and Improved Quality</strong>: The elimination of welding not only reduced potential points of failure but also led to a&nbsp;<strong>10% reduction in scrap rates</strong>. Moreover, with fewer assembly steps, the overall quality and consistency of the components improved, ensuring better long-term reliability.<br><br></p></li><li data-list-indent="1" data-list-type="numbered"><p><strong>Streamlined Supply Chain and Reduced Storage Requirements</strong>: Since 3D printing enables the on-demand production of parts, INDEX was able to reduce its storage needs by <strong>66%</strong>, further optimizing its production environment.</p></li></ol><p><br></p><p><strong>Conclusion: Metal 3D Printing for Serial Production</strong></p><p>The case study from INDEX-Werke underlines the impact of metal 3D printing in serial production. Through the application of LPBF technology, INDEX was able to reduce costs, shorten lead times, and improve the overall efficiency of its manufacturing processes.&nbsp;</p>

Serial production of the slider trolley for INDEX-Werke

How additive manufacturing can improve efficiency in leading manufacturing companies like INDEX group.

Enabling Serial Production with Metal 3D Printing

Flame test with a lighter on an FDM ULTEM 9085 part

This article delves into flame-retardant plastics typically used to produce parts through 3D printing, CNC machining, and formative manufacturing technologies. It also covers the complexities of flame retardancy and industry standards, such as the UL 94 rating.

Flame Retardant Plastics & UL 94 Flammability Standards In Parts Manufacturing

This article overviews CNC machining and injection molding as popular manufacturing technologies to produce mechanical parts, such as connectors, heat sinks and housings, for end-customer electronics devices.

CNC Machining and Injection Molding to Produce Mechanical Parts for the Electronics Industry

<p dir="ltr" id="isPasted">Regardless of the industry, shorter development and innovation cycles can lead to improved market performance. Faster prototyping means faster testing and validation, which in turn produces faster development and product launches. This compressed development cycle can then give a company an edge over its competitors, providing its customers with the most cutting-edge solutions.</p><p dir="ltr">Unfortunately, various bottlenecks can slow down the development cycle, perhaps the most significant of these being supplier sourcing or procurement. An R&amp;D department might come up with several feasible product designs per day, but that counts for nothing if prototypes and components cannot be sourced in a timely manner. Finding a supplier, arranging a contract, waiting for shipments, then coordinating the process with other contractors can turn a cutting-edge product into an obsolete one.</p><p dir="ltr">Streamlined procurement is therefore key to efficient product development. But how can that be achieved when an engineer sometimes works with separate parties for technical consulting, manufacturing, post-processing, and surface finishing?</p><h1 dir="ltr">Streamlined Procurement with FACTUREE</h1><p dir="ltr">Manufacturing hub FACTUREE, based in Berlin's iconic Osram-Höfe industrial business park, has addressed the issue of procurement complexity by offering a seamless process that connects customers with the right suppliers for every need, all managed through a single point of contact. Instead of dealing with multiple suppliers, customers benefit from FACTUREE's extensive network of over 2,000 qualified suppliers, all managed by FACTUREE to ensure the best match for every requirement.</p><p dir="ltr">Finding suppliers can be one of the most frustratingly slow processes in the development cycle: companies need to find suppliers offering immediate machine availability, fast shipment, and a fair quotation — and checking all three of these boxes isn't always possible. In fact, <a href="https://www.facturee.de/en/facturee-procurement-study-26-percent-of-companies-see-high-effort-in-supplier-coordination-as-an-obstacle/" target="_blank">26 percent of companies</a> take issue with the effort required to coordinate suppliers when procuring components.&nbsp;</p><p dir="ltr">However, with FACTUREE, customers no longer need to navigate the time-consuming process themselves. FACTUREE's digital solution efficiently manages an extensive network of qualified suppliers, ensuring that every project is matched with the best manufacturer. FACTUREE simplifies procurement for its clients by finding tailored solutions for every requirement, regardless of the quantity or complexity, and efficiently managing the entire process.&nbsp;</p><p dir="ltr">One of the ways FACTUREE tackles the issue of supplier sourcing is through digital procurement. This means that a company uses a single digital platform to rapidly identify available suppliers for every production stage, from technical analysis to surface finishing. Moreover, FACTUREE serves as the single point of contact, managing all required liaisons and coordination between suppliers, ensuring a smooth, stress-free process that enables the end user to get their project moving almost instantly. FACTUREE utilizes cutting-edge digital technologies and artificial intelligence to improve the traditional procurement process. Their intelligent algorithms optimize supplier selection, while automated processes ensure that projects are executed efficiently and on time. This AI-supported selection ensures that the best possible finisher is chosen for each project, guaranteeing high-quality outcomes. These digital solutions enable FACTUREE's customers to respond more quickly to market changes and bring innovative ideas to life in the shortest possible time.</p><p dir="ltr">FACTUREE acts as a strategic partner in procurement, finding the ideal manufacturer for every need and ensuring that the process is as efficient and hassle-free as possible. Through partnership, FACTUREE drives progress and creates new opportunities for innovation. They are dedicated to understanding engineers' challenges and offering tailored solutions that meet their specific needs.</p><p dir="ltr"><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzI2MDY4MzUyNTg4LWZhY3R1cmVlIDEucG5nIiwiZWRpdHMiOnsicmVzaXplIjp7IndpZHRoIjo5NTAsImZpdCI6ImNvdmVyIn19fQ==" style="width: 100%px;" class="fr-fic fr-dib"></p><h1 dir="ltr" id="isPasted">Free Advanced Tools for Manufacturing</h1><p dir="ltr">FACTUREE's approach can dramatically shorten product development cycles, and it can be applied to various forms of manufacturing, including additive manufacturing, CNC machining, sheet metal fabrication, and, as of 2024, molding and casting processes. This is in addition to surface finishing processes, large-scale series production, and other unique offerings, all enabled by FACTUREE's network of over 2,000 trusted manufacturing partners and their 15,000 individual machines.</p><p dir="ltr">To ensure a successfully manufactured part, FACTUREE also provides free advanced tools that can help engineers with standards, fit, and tolerances. For the last few years, FACTUREE has provided two highly useful online tools to assist engineers with design and development before they send their technical drawings for manufacturing.</p><p dir="ltr">The first of these tools is the <a href="https://www.facturee.de/en/online-tools/rz-ra-calculator/" target="_blank">Rz-Ra Calculator</a>, an industry-first online solution for converting surface roughness parameters. This is important for engineers because customers across different industries may prefer certain parameters for measuring roughness over others. For example, Ra indicates average height deviations (and corresponds to ISO N standards) while Rz indicates maximum peak-to-valley heights or extreme irregularities. The more relevant value depends on the application of the part. Another advanced tool offered by FACTUREE is an <a href="https://www.facturee.de/en/online-tools/" target="_blank">optimized fit calculator</a>. This tool calculates the maximum tolerance for a given dimension and type of fit and provides a unique reciprocal calculation function, working out clearance fit and other fit classes from a specified internal and external fit value.</p><p dir="ltr"><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzI2MDY4NDMyNzg3LWdyYXBoLmpwZyIsImVkaXRzIjp7InJlc2l6ZSI6eyJ3aWR0aCI6OTUwLCJmaXQiOiJjb3ZlciJ9fX0=" style="width: 100%px;" class="fr-fic fr-dib"></p><h1 dir="ltr" id="isPasted">FACTUREE Success Stories</h1><p dir="ltr">The seamless procurement solution from FACTUREE has been leveraged by many companies, large and small, across several industries. One success story was demonstrated in 2023 when ten taxi ranks and 66 electric vehicles in the Austrian cities of Vienna and Graz had to be retrofitted with all-new Matrix Charging stations from tech company Easelink. This automated, hands-free charging station makes life easier for drivers and is helping to facilitate the "eTaxi Austria" scheme to make all taxis electric by 2025.</p><p dir="ltr">As part of the project, FACTUREE was tasked with supplying key components for the core element of the conductive charging system. For one of the two core components, various small-turned and milled aluminum parts were required. Because FACTUREE could leverage its wide range of manufacturing partners, manufacturing techniques, and surface treatments, it could meet Easelink's demands nimbly and efficiently — faster than if the customer had sourced suppliers on its own.</p><p dir="ltr"><span class="fr-img-caption fr-fic fr-dib" style="width: 832px;"><span class="fr-img-wrap"><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzI2MDY4NTY2Mzg2LWNhciBjYXIuanBnIiwiZWRpdHMiOnsicmVzaXplIjp7IndpZHRoIjo5NTAsImZpdCI6ImNvdmVyIn19fQ==" style="width: 100%px;" class="fr-fic fr-dib"><span class="fr-inner">FACTUREE supplied various small-turned and milled parts made of aluminum for the connector. Credit: Facturee</span></span></span></p><p dir="ltr" id="isPasted">Another beneficiary of FACTUREE's services is aerospace company Space Applications Services, headquartered in Brussels, whose customers include organizations like the European Space Agency (ESA). The company required CNC machined parts for prototypes and space qualification models used in aerospace applications after its previous supplier failed to meet expectations regarding material quality, delivery times, and pricing. The high-quality parts supplied by FACTUREE have convinced Space Applications Services to continue using the service after more than two years.</p><h1 dir="ltr">Conclusion</h1><p dir="ltr">Finding suppliers to handle part manufacturing, post-processing, finishing, and other tasks is a challenge that adds unnecessary time and complexity to product development. By entrusting procurement to FACTUREE, companies can focus on innovation while FACTUREE manages the complexities, ensuring a smooth, efficient process from start to finish.</p><p>Visit the FACTUREE&nbsp;website to<a href="https://www.facturee.de/en/inquiry/" target="_blank">&nbsp;directly request a quote</a>, or contact them with any questions to schedule a consultation.&nbsp;</p><p><em>This article was contributed to by Benedict O'Neil</em></p>

Engineers, procurement managers, and other manufacturing professionals can streamline procurement and enhance productivity through FACTUREE's vision to simplify sourcing, reduce complexity, and save valuable time and resources by providing a single point of contact.

AI-Driven Procurement Solutions for Streamlined Engineering and Manufacturing

<p id="isPasted">Choosing right tolerance is essential for any engineering project because it determines its future application possibilities, lead time, and price.&nbsp;</p><p>Designers and engineers add tolerances&nbsp;to the drawing specifications to ensure that the size and geometry of the features on component parts are controlled. However, adding tolerances to every single feature of a part can be time consuming and inefficient. That’s why the use of certain standardised tolerance values is a regular practice nowadays (read more about tolerances in CNC Machining).</p><p>In Europe and many other parts of the world, these values are defined by ISO tolerance standards. These standards stipulate tolerance values for different part geometries and are further divided into classes and grades with different levels of quality.</p><p>Tolerance standards often reduce the work of designers. Instead of calculating tolerances for every geometry and feature in a model, they can simply make use of the standard that matches their desired quality level.</p><h2 data-counter-attr="value0"><strong>Tolerance Standards Used in Europe</strong></h2><p>Tolerance standards vary depending on the manufacturing processes. For example, the most common tolerance standards that are used by engineers in Europe for subtractive manufacturing (e.g. CNC machining) are defined by ISO 2768 and ISO 286. At Xometry we offer 5 options:</p><ul><li>ISO 2768 – Fine</li><li>ISO 2768 – Medium</li><li>ISO 286 – Grade 6</li><li>ISO 286 – Grade 7</li><li>ISO 286 – Grade 8</li></ul><p>The main difference between ISO 286 and 2768 is that ISO 2768 covers general tolerances ranges for linear and angular dimensions, ISO 286 covers general tolerances ranges for cylinders and opposite parallel surfaces, for example, for shaft and hole systems. These tolerance standards can be used in parallel to each other, if the design has the features that both of them cover.</p><p><span class="fr-img-caption fr-fic fr-dib" style="width: 832px;"><span class="fr-img-wrap"><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1724646277605-General-tolerance-indicated-on-a-technical-drawing.webp" style="width: 100%px;" class="fr-fic fr-dib"><span class="fr-inner">General tolerance indicated on a technical drawing</span></span></span></p><p id="isPasted">The table below gives a concise summary of these tolerance standards. More elaborate explanations of the standards are provided later in the article.</p><p>Here’s a short overview of the main differences in tolerances:</p><table><thead><tr><th>Tolerance Standard&nbsp;</th><th>General Linear Tolerances&nbsp;</th><th>General Tolerances for External Radius and Chamfer Heights&nbsp;</th><th>Angular Dimensions</th></tr></thead><tbody><tr><td>ISO 2768 – Medium (Standard)</td><td>±0.1-2 mm depending on the nominal length from 0.5 to over 2000 mm</td><td>±0.2-1 mm depending on the nominal length from 0.5 to over 6 mm</td><td>±1°-0°5’ depending on the nominal length from up to 10 to over 400 mm</td></tr><tr><td>ISO 2768 – Fine</td><td>±0.05-0.5 mm depending on the nominal length from 0.5 to over 2000 mm</td><td>±0.2-1 mm depending on the nominal length from 0.5 to over 6 mm</td><td>±1°-0°5’ depending on the nominal length from up to 10 to over 400 mm</td></tr><tr><td>ISO 286 – Grade 8</td><td colspan="3">Standardized tolerance value ranges from 0.014 to 0.23 mm depending on the nominal size from 0.5 to 2000 mm</td></tr><tr><td>ISO 286 – Grade 7</td><td colspan="3">Standardized tolerance value ranges from 0.010 to 0.150 mm depending on the nominal size from 0.5 to 2000 mm</td></tr><tr><td>ISO 286 – Grade 6</td><td colspan="3">Standardized tolerance value ranges from 0.006 to 0.092 mm depending on the nominal size from 0.5 to 2000 mm</td></tr></tbody></table><h2 data-counter-attr="value1"><strong>ISO 2768</strong></h2><p>ISO 2768 and the derived geometrical tolerance standards are mainly employed for parts that are manufactured by machining or other material removing processes.</p><p>The ISO 2768 only applies to the following drawings with the following features. It is used when these features do not have custom tolerance indications individually:</p><ul><li>Linear dimensions (external sizes, internal sizes, diameters, distances, chamfer heights, radii)</li><li>Angular dimensions</li><li>Linear and angular dimensions produced by machining assembled parts.</li></ul><h3 data-counter-attr="value2"><strong>Linear Dimensions</strong></h3><table><thead><tr><th>Nominal Length (mm)&nbsp;</th><th>Tolerance Class Values (mm)</th></tr></thead><tbody><tr><td><strong>Above</strong></td><td><strong>Up to and including</strong></td><td><strong>Fine</strong></td><td><strong>Medium</strong></td></tr><tr><td>0.5</td><td>3</td><td>±0.05</td><td>±0.1</td></tr><tr><td>3</td><td>6</td><td>±0.05</td><td>±0.1</td></tr><tr><td>6</td><td>30</td><td>±0.1</td><td>±0.2</td></tr><tr><td>30</td><td>120</td><td>±0.15</td><td>±0.3</td></tr><tr><td>120</td><td>400</td><td>±0.2</td><td>±0.5</td></tr><tr><td>400</td><td>1000</td><td>±0.3</td><td>±0.8</td></tr><tr><td>1000</td><td>2000</td><td>±0.5</td><td>±1.2</td></tr><tr><td>2000</td><td>4000</td><td>–</td><td>±2.0</td></tr></tbody></table><h3 data-counter-attr="value3"><strong>External Radius and Chamfer Heights</strong></h3><table><thead><tr><th>Nominal Length (mm)&nbsp;</th><th>Tolerance Class Values (mm)</th></tr></thead><tbody><tr><td><strong>Above</strong></td><td><strong>Up to and including</strong></td><td><strong>Fine</strong></td><td><strong>Medium</strong></td></tr><tr><td>0.5</td><td>3</td><td>±0.2</td><td>±0.2</td></tr><tr><td>3</td><td>6</td><td>±0.5</td><td>±0.5</td></tr><tr><td>6</td><td>Above</td><td>±1.0</td><td>±1.0</td></tr></tbody></table><h3 data-counter-attr="value4"><strong>Angular Dimensions</strong></h3><table><thead><tr><th>Nominal Size (mm)&nbsp;</th><th>Tolerance Class Values (°,ˈ )</th></tr></thead><tbody><tr><td><strong>Above</strong></td><td><strong>Up to and including</strong></td><td><strong>Fine</strong></td><td><strong>Medium</strong></td></tr><tr><td>–</td><td>10</td><td>±1°</td><td>±1°</td></tr><tr><td>10</td><td>50</td><td>±0°30ˈ</td><td>±0°30ˈ</td></tr><tr><td>50</td><td>120</td><td>±0°20ˈ</td><td>±0°20ˈ</td></tr><tr><td>120</td><td>400</td><td>±0°10ˈ</td><td>±0°10ˈ</td></tr><tr><td>400</td><td>Above</td><td>±0°5ˈ</td><td>±0°5ˈ</td></tr></tbody></table><h2 data-counter-attr="value5"><strong>ISO 286</strong></h2><p>The ISO 286 applies to subtractive manufacturing methods and provides tolerances to be used for linear sizes of the following types of features:</p><ul><li>Cylinder</li><li>2 parallel opposite surfaces</li></ul><p>This tolerance only applies drawings with these features. It is used when these features do not have custom tolerance indications individually. We offer three quality grades under the ISO 286 standard. They are grade 6 (IT6), grade 7 (IT7), and grade 8 (IT8).</p><p>The ISO 286 provides a standardized selection of tolerance classes for general purposes from amongst the numerous possibilities.</p><p><strong>According to the ISO 286 standard, the following terms apply:</strong></p><ol><li><strong>Nominal Size:</strong> This is the size of a feature as defined by the drawing specifications</li><li><strong>Actual size:</strong> This is the size obtained by measurement</li><li><strong>Upper limit of size:</strong> The is the largest permissible size of the feature</li><li><strong>Lower limit of size:</strong> This is smallest permissible size of the feature</li><li><strong>Tolerance:&nbsp;</strong>Difference between the upper limit of size and the lower limit of size.</li></ol><table><thead><tr><th>Nominal Size (mm)</th><th>Standard Ranges of Tolerance Grade</th></tr></thead><tbody><tr><td>Above</td><td>Up to and including</td><td>IT6</td><td>IT7</td><td>IT8</td></tr><tr><td>–</td><td>3</td><td>0.006</td><td>0.010</td><td>0.014</td></tr><tr><td>3</td><td>6</td><td>0.008</td><td>0.012</td><td>0.018</td></tr><tr><td>6</td><td>10</td><td>0.009</td><td>0.015</td><td>0.022</td></tr><tr><td>10</td><td>18</td><td>0.011</td><td>0.018</td><td>0.027</td></tr><tr><td>18</td><td>30</td><td>0.013</td><td>0.021</td><td>0.033</td></tr><tr><td>30</td><td>50</td><td>0.016</td><td>0.025</td><td>0.039</td></tr><tr><td>50</td><td>80</td><td>0.019</td><td>0.030</td><td>0.046</td></tr><tr><td>80</td><td>180</td><td>0.022</td><td>0.035</td><td>0.054</td></tr><tr><td>120</td><td>180</td><td>0.025</td><td>0.040</td><td>0.063</td></tr><tr><td>180</td><td>250</td><td>0.029</td><td>0.046</td><td>0.072</td></tr><tr><td>250</td><td>315</td><td>0.032</td><td>0.052</td><td>0.081</td></tr><tr><td>315</td><td>400</td><td>0.036</td><td>0.057</td><td>0.089</td></tr><tr><td>400</td><td>500</td><td>0.040</td><td>0.063</td><td>0.097</td></tr><tr><td>500</td><td>630</td><td>0.044</td><td>0.070</td><td>0.110</td></tr><tr><td>630</td><td>800</td><td>0.050</td><td>0.080</td><td>0.125</td></tr><tr><td>800</td><td>1000</td><td>0.056</td><td>0.090</td><td>0.140</td></tr><tr><td>1000</td><td>1250</td><td>0.066</td><td>0.105</td><td>0.165</td></tr><tr><td>1250</td><td>1600</td><td>0.078</td><td>0.125</td><td>0.195</td></tr><tr><td>1600</td><td>2000</td><td>0.092</td><td>0.150</td><td>0.230</td></tr><tr><td>2000</td><td>2500</td><td>0.110</td><td>0.175</td><td>0.280</td></tr><tr><td>2500</td><td>3150</td><td>0.135</td><td>0.210</td><td>0.330</td></tr></tbody></table><h2 data-counter-attr="value6"><strong>Equivalent US Standards</strong></h2><p>Tolerance standards applied in Europe (ISO) have their equivalent US counterparts (ASME). There are a number of differences between the ISO and ASME tolerance standards.</p><p>The table below shows the equivalent US standards of some European tolerance standards.</p><table><thead><tr><th>Standard</th><th>ISO 2768 (fine)</th><th>ISO 2768 (medium)</th><th>ISO 268 grade 6</th><th>ISO 268 grade 7</th><th>ISO 268 grade 8</th></tr></thead><tbody><tr><td>Equivalent US standard</td><td>–</td><td>–</td><td>ASME B4.1 Grade 6</td><td>ASME B4.1 Grade 7</td><td>ASME B4.1 Grade 8</td></tr></tbody></table><h2 data-counter-attr="value7"><strong>Conclusion</strong></h2><p>These tolerance standards are used in place of custom tolerancing. Upload your models for CNC machining on our instant quoting platform and select one of the five listed classes and grades. If your part requires custom tolerances, you would need to also upload the necessary part drawings.&nbsp;</p>

Choosing right tolerance is essential for any engineering project because it determines its future application possibilities, lead time, and price. 

Subtractive Manufacturing Tolerance Standards Overview

<p id="isPasted">APSX Machines are relevant to the IMTS 2024 audience because the IMTS (International Manufacturing Technology Show) is a major trade show that showcases the latest advancements in manufacturing technology, including machine tools, robotics, and automation equipment. APSX Machines, which specializes in advanced manufacturing solutions, would be of interest to the IMTS audience, consisting of industry professionals, manufacturers, and engineers looking to explore new technologies and innovations that can enhance their manufacturing processes and productivity.&nbsp;</p><h2>Smart Manufacturing: The Role of APSX Machines at IMTS 2024</h2><p>As the manufacturing industry continues to evolve, smart manufacturing has emerged as a key trend. APSX Machines play a crucial role in this transformation by offering advanced, automated solutions that enhance productivity and efficiency. At IMTS 2024, attendees will have the opportunity to see and hear firsthand how APSX Machines integrate cutting-edge technology to streamline manufacturing processes.</p><h2>APSX machines are available to purchase with listed pricing and they are in stock to be shipped</h2><p>One of the key advantages of APSX Machines is their availability. Unlike many other industrial machines that require long lead times, APSX Machines can be purchased quickly, with transparent pricing listed upfront (visit <a href="http://www.apsx.com/" target="_blank">www.apsx.com</a>). This allows businesses to make informed decisions and plan their budgets effectively.</p><p>Moreover, APSX Machines are in stock and ready to be shipped, reducing the wait time. This immediate availability ensures that manufacturers can quickly integrate these machines into their production methods, accelerating the transition to more efficient operations.</p><h2>Great opportunities for rapid prototyping and production by using the APSX machines</h2><p>APSX Machines offer equipment like CNC machines and injection molding machines that are ideal for rapid prototyping. This allows manufacturers to quickly create prototypes and iterate designs, significantly reducing development time and costs.</p><p>APSX Machines are designed to facilitate rapid prototyping and production, making them ideal for businesses looking to innovate and bring new products to market swiftly. Their advanced capabilities allow for the quick creation of prototypes, enabling iterative testing and refinement without significant delays. Short setup times, quick learning curves lead to real and functional parts faster and cheaper.&nbsp;</p><p>This rapid prototyping capability not only speeds up the development process but also reduces costs associated with traditional prototyping methods. By using APSX Machines, manufacturers can achieve a faster time-to-market, giving them a competitive edge in the industry.</p><h2>APSX machines allows you to adapt to flexible and responsive production needs</h2><p>The machines are versatile, allowing for a wide range of materials and applications. This flexibility is crucial for IMTS attendees who work in diverse industries and need equipment that can adapt to various manufacturing needs.</p><p>In today's dynamic market, the ability to adapt to changing production needs is crucial. APSX Machines offer the flexibility and responsiveness required to meet these demands. Whether it's scaling up production in response to increased demand or customizing products to meet specific customer requirements, APSX Machines provide the necessary agility.</p><p>Their versatile design and easy reconfiguration make it possible to switch between different production tasks seamlessly. This adaptability ensures that businesses can respond quickly to market changes, maintaining their competitive edge and meeting customer expectations.</p><h2>APSX machines offer minimum initial investment and ongoing operational costs</h2><p>APSX Machines are designed to be cost-effective, which makes them accessible for small to medium-sized enterprises (SMEs). For example, their compact injection molding machines can produce parts in-house, reducing the need for outsourcing and cutting down on production costs.</p><p>Investing in new manufacturing equipment can be a significant financial commitment. However, APSX Machines are designed to minimize initial investment and ongoing operational costs. Their cost-effective pricing model allows businesses to acquire high-quality machinery without breaking the bank.</p><p>Additionally, APSX Machines are built for efficiency, reducing energy consumption and maintenance requirements. This not only lowers operational costs but also contributes to a more sustainable manufacturing process. By choosing APSX Machines, manufacturers can achieve long-term savings while maintaining high levels of productivity and efficiency.</p><p><a href="https://www.linkedin.com/feed/hashtag/?keywords=cncmachining&highlightedUpdateUrns=urn%3Ali%3Aactivity%3A7233571251003269120" data-test-app-aware-link="" target="_blank" id="isPasted">#cncmachining</a> <a href="https://www.linkedin.com/feed/hashtag/?keywords=injectionmolding&highlightedUpdateUrns=urn%3Ali%3Aactivity%3A7233571251003269120" data-test-app-aware-link="" target="_blank">#injectionmolding</a> <a href="https://www.linkedin.com/feed/hashtag/?keywords=rapidprototyping&highlightedUpdateUrns=urn%3Ali%3Aactivity%3A7233571251003269120" data-test-app-aware-link="" target="_blank">#rapidprototyping</a> <a href="https://www.linkedin.com/feed/hashtag/?keywords=swisslathe&highlightedUpdateUrns=urn%3Ali%3Aactivity%3A7233571251003269120" data-test-app-aware-link="" target="_blank">#swisslathe</a> <a href="https://www.linkedin.com/feed/hashtag/?keywords=productdesign&highlightedUpdateUrns=urn%3Ali%3Aactivity%3A7233571251003269120" data-test-app-aware-link="" target="_blank">#productdesign</a></p><p><br></p>

Discover how APSX Machines are transforming the manufacturing landscape and what IMTS 2024 attendees can look forward to.

APSX Machines: Key Highlights for IMTS 2024 Attendees

<p id="isPasted"><a href="https://xometry.eu/en/cnc-machining/" target="_blank" rel="noreferrer noopener">CNC machining</a> is a highly accurate and precise manufacturing process that can create parts with tolerances as tight as 0.025 mm. However, being a subtractive manufacturing method, CNC machining leaves cut marks that create a level of roughness on the finished product’s surface.</p><h2 data-counter-attr="value0"><strong>What is Surface Roughness?</strong></h2><p>Surface roughness is a measure of the average texture of a part’s surface, in this case, after CNC machining. There are different parameters used to define surface roughness. One of the most ubiquitous of these is Ra (Roughness average), which is derived from the differences between heights and depths on a surface. Ra surface roughness is measured microscopically and is usually in micrometres (x 10~⁶ m). Note that surface roughness in this context is different from surface finish. The surface finish of a machined part can be improved via various finishing methods such as anodizing, bead blasting, and electroplating. Surface roughness here refers to the as-machined surface texture of a part.</p><h2 data-counter-attr="value1"><strong>How Are Different Surface Roughness Options Achieved?</strong></h2><p>A part’s surface roughness after machining is usually not random. Instead, steps are taken to ensure that a specific roughness is achieved. This means that surface roughness values are planned in advance. However, not just any value is usually specified. In manufacturing, there are specific Ra values that are considered industry standards, as specified in <a href="https://guide.digitalsurf.com/en/guide-iso-4287-parameters.html" target="_blank" rel="noreferrer noopener">ISO 4287.</a> These are the values that may be specified during CNC machining. They range from 25 μm to 0.025 μm and apply to all kinds of manufacturing and post-processing operations.</p><p><strong>At Xometry Europe, we offer four surface roughness levels that are also the values typically specified for CNC Machining applications:</strong></p><ul><li>3.2 μm Ra</li><li>1.6 μm Ra</li><li>0.8 μm Ra</li><li>0.4 μm Ra</li></ul><p>Different roughness values are required for different applications. Lower surface roughnesses should only be specified when necessary. This is because the lower the Ra value, the more machining effort/operations and quality control will be required. They can significantly drive up machining costs and time. Post-processing operations aren’t usually applied when specific surface roughness values are required. This is because these operations cannot be controlled precisely and may affect the dimensional tolerance of parts.</p><p><span class="fr-img-caption fr-fic fr-dib" style="width: 832px;"><span class="fr-img-wrap"><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1723617196640-Surface-roughness-for-CNC-milling-and-turning-compared.webp" style="width: 100%px;" class="fr-fic fr-dib"><span class="fr-inner">Surface roughness for CNC milling and turning compared</span></span></span></p><p id="isPasted">Surface roughness significantly affects the functionality, performance, and durability of parts in certain applications. It influences the <a href="https://www.engineeringtoolbox.com/friction-coefficients-d_778.html" target="_blank" rel="noreferrer noopener">friction coefficient</a>, noise level, wear and tear, heat, and adhesiveness of a part in use. The importance of these factors vary by application, and so while the surface roughness of a part is inconsequential in certain applications, it is critical in many others. These applications include high tension, stress, and vibration scenarios, mating and moving assemblies, fast rotating parts, and medical implants. As earlier stated, different levels of surface roughness are required in different applications.</p><p>The following explores the roughness levels that we offer at Xometry Europe and all you need to know in order to select the right Ra value for your application.</p><h2 data-counter-attr="value2"><strong>3.2 μm Ra</strong></h2><p>This is the standard commercial machine finish. It is suitable for most consumer parts and sufficiently smooth, but it contains visible cut marks. It is the default surface roughness applied unless otherwise is specified.</p><p>3.2 μm Ra is the recommended maximum surface roughness for parts subject to stress, loads, and vibrations. It can also be used for mating moving surfaces when the load is light and motion slow. It is machined using high speeds, fine feeds, and light cuts.</p><p><span class="fr-img-caption fr-fic fr-dib" style="width: 832px;"><span class="fr-img-wrap"><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1723617228659-machined-marks.webp" style="width: 100%px;" class="fr-fic fr-dib"><span class="fr-inner">3.2 μm Ra as machined cut marks</span></span></span></p><h2 data-counter-attr="value3" id="isPasted"><strong>1.6 μm Ra</strong></h2><p>Usually, there are only slightly visible cut marks with this option. This Ra rating is recommended for tight fits and stressed parts, and is sufficient for slow-moving and light load-bearing surfaces. However, it is not suitable for fast rotating parts and parts subject to intense vibration. This surface roughness is produced using high speeds, fine feeds, and light cuts under controlled conditions.</p><p><strong>Price:&nbsp;</strong>for a standard aluminium alloy (e.g. 3.1645) this option adds approximately 2,5% to the production price. This could increase with the complexity of the part.</p><h2 data-counter-attr="value4"><strong>0.8 μm Ra</strong></h2><p>Considered high grade, this surface finish requires very close control to produce, costing more. It is required for parts that are exposed to stress concentration. When the motion is occasional and the loads are light, then it can be used for bearings.</p><p><strong>Price:&nbsp;</strong>for a standard aluminium alloy (e.g. 3.1645) this option adds approximately 5% to the production price. This could increase with the complexity of the part.</p><h2 data-counter-attr="value5"><strong>0.4 μm Ra</strong></h2><p>This is the finest (“least rough” in technical terms) and highest quality surface roughness that are offered. It is suitable for parts that are under high tension or stress. It is also required for rapidly rotating components such as bearings and shafts. This surface roughness takes the most effort to manufacture and should only be specified when smoothness is of primary importance.&nbsp;</p><p><strong>Price:&nbsp;</strong>for a standard aluminium alloy (e.g. 3.1645) this option adds approximately 11-15% to the production price. This could increase with the complexity of the part.</p><p>At Xometry, we can manufacture your <a href="https://xometry.eu/en/cnc-machining/" target="_blank">CNC machined parts</a> with any of these surface roughnesses options. Simply upload your model on our <a href="https://get.xometry.eu/?locale=en" target="_blank">instant quoting platform</a> and select your preferred surface roughness to get a quote in a second.&nbsp;</p>

The article overviews standard surface roughness options for CNC machining and their application (from 3.2 to 0.4 μm Ra).

Selecting Right Surface Roughness for CNC Machining

<p id="isPasted"><strong>Optimizing CNC Machining of Aluminum Parts: The Role of Single Flute End Mills and Cutting Parameters</strong></p><p>In CNC machining, particularly when drilling aluminum parts, the choice of cutting tools and parameters is crucial for achieving optimal performance and precision. Single flute end mills, with their unique design and benefits, are a preferred choice for machining aluminum due to their efficiency in chip removal and reduced cutting forces.&nbsp;</p><h3>Technical Overview of Single Flute End Mills</h3><p>Single flute end mills are characterized by their single helical cutting edge, which is specifically designed to handle the high-speed, high-efficiency requirements of machining operations. Here’s a closer look at the technical advantages they offer:</p><ul><li><p><strong>Chip Removal Efficiency</strong>: The single flute design allows for rapid evacuation of chips, which is crucial when drilling aluminum. Efficient chip removal minimizes the risk of chip re-cutting and ensures a cleaner cutting process.</p></li><li><p><strong>Reduced Cutting Forces</strong>: With only one cutting edge engaging with the material, the forces applied during cutting are significantly reduced. This enables higher feed rates and cutting speeds without compromising tool stability.</p></li><li><p><strong>Increased Cutting Speed</strong>: Single flute end mills can operate at higher rotational speeds compared to multi-flute tools due to their reduced cutting forces. This capability enhances productivity by shortening cycle times.</p></li></ul><h3>CNC Cutting Parameters for Single Flute End Mills</h3><p>When using single flute end mills for CNC machining of aluminum blocks, precise control of cutting parameters is essential for optimal performance. The following guidelines offer a starting point for configuring your CNC machine settings:</p><h4>1.&nbsp;<strong>Cutting Speed (Spindle Speed)</strong></h4><ul><li><strong>Recommended Range</strong>: 15,000 to 25,000 RPM</li><li><strong>Factors to Consider</strong>: Cutting speed should be adjusted based on the diameter of the end mill and the specific grade of aluminum being machined. Smaller diameter end mills can typically handle higher RPMs, while larger diameters may require lower speeds to avoid excessive tool wear.</li></ul><h4>2.&nbsp;<strong>Feed Rate</strong></h4><ul><li><strong>Recommended Range</strong>: 0.005&nbsp;to 0.010 inches per tooth (IPT)</li><li><strong>Factors to Consider</strong>: Feed rate should be optimized to balance cutting efficiency with tool life. Higher feed rates can increase productivity but may require adjustments to spindle speed and coolant usage to maintain optimal cutting conditions.</li></ul><h4>3.&nbsp;<strong>Depth of Cut</strong></h4><ul><li><strong>Recommended Range</strong>: 0.025 to 0.05 inches per pass</li><li><strong>Factors to Consider</strong>: The depth of cut affects both chip removal and tool stability. For deeper cuts, consider making multiple passes to avoid overloading the end mill and to ensure a smoother finish.</li></ul><h4>4.&nbsp;<strong>Width of Cut (Stepover)</strong></h4><ul><li><strong>Recommended Range</strong>: 0.1 to 0.5 times the end mill diameter</li><li><strong>Factors to Consider</strong>: The stepover value should be chosen to achieve the desired surface finish while balancing tool wear and machining time. A smaller stepover results in finer finishes but increases machining time.</li></ul><h4>5.&nbsp;<strong>Coolant and Lubrication</strong></h4><ul><li><strong>Recommended Types</strong>: Air blast, mist coolant, or flood coolant</li><li><strong>Factors to Consider</strong>: Effective cooling is crucial to prevent overheating and maintain tool life. For aluminum, using a coolant can help manage heat and reduce the risk of material adhesion to the cutting tool.</li></ul><h3>Advanced Tips for Single Flute End Mills in CNC Machining</h3><ul><li><p><strong>Tool Path Optimization</strong>: Use optimized tool paths such as trochoidal milling for improved chip removal and reduced cutting forces. This technique helps maintain consistent cutting conditions and enhances tool life.</p></li><li><p><strong>Tool Wear Monitoring</strong>: Regularly inspect the end mill for signs of wear or damage. Implement tool wear monitoring techniques to predict and schedule tool changes, minimizing downtime and maintaining machining accuracy.</p></li><li><p><strong>Material-Specific Adjustments</strong>: Adjust parameters based on the specific alloy of aluminum being machined. Different alloys can have varying hardness and machinability characteristics, which may require fine-tuning of cutting speeds and feed rates.</p></li></ul><h3>Conclusion</h3><p>Single flute end mills are highly effective for CNC machining of aluminum blocks, offering advantages in chip removal, cutting forces, and cutting speeds. By carefully configuring CNC cutting parameters such as spindle speed, feed rate, depth of cut, and coolant usage, you can optimize performance and achieve high-quality results in your machining operations.</p><p>Experiment with these parameters and monitor the results to fine-tune your processes for specific applications when you use either the <a href="https://www.apsx.com/apsx-nano-cnc-swiss-lathe" target="_blank" rel="noopener noreferrer">APSX-NANO Swiss CNC Lathe</a> or <a href="https://www.apsx.com/desktop-cnc-machine" target="_blank" rel="noopener noreferrer">Spyder CNC</a>. With the right setup, single flute end mills can enhance productivity, extend tool life, and improve the overall quality of your machined parts.</p><p>Happy machining, and may your CNC operations be efficient and precise!</p>

With the right setup, single flute end mills can enhance productivity, extend tool life, and improve the overall quality of your machined parts.

Innovative Ways of Using a Single Flute End Mill on A CNC Machine - Drilling - Boring

<p dir="ltr" id="isPasted">An interesting observation from RPWORLD’s experienced manufacturing engineers: Over 10 years ago, different custom mechanical parts often had a mix of different strict and loose tolerances. However, in recent years, mechanical parts of different applications frequently have very strict tolerances and high precision, even for surfaces where high dimensional accuracy and surface quality are not crucial. This reflects industrial progress, but actually some of these stringent requirements are unnecessary. Today, let's discuss a major misunderstanding about CNC machining tolerances.</p><h2 dir="ltr">A Misunderstanding about CNC Machining Tolerances</h2><p dir="ltr">People often believe that tight tolerance can improve product quality. Actually, tight part tolerances only indicate a high production quality for individual parts, and do not directly equate to higher product quality. Product quality is ultimately presented through the assembly of parts. However, the tighter the tolerances for parts, the higher the manufacturing costs and product costs. For instance, an overly stringent tolerance might require that parts go to a secondary grinding or EDM operation for completion, unnecessarily increasing costs and lead-time. The relationship between the machining cost and part is shown in the following figure.</p><p dir="ltr">Meanwhile, tolerances that are “too loose” or that aren’t in line with those of mating parts can make assembly impossible, leading to required rework, or in the worst case, making the finished product unusable. Therefore, while meeting product function and quality’s requirements, the tolerance requirements for parts should be reasonably set to reduce product manufacturing costs.</p><h2 dir="ltr">How to Set Reasonable Part Tolerance for Product Design?</h2><h3 dir="ltr">1. Design Reasonable Gap</h3><p dir="ltr">In the assembly relationships of parts, there are situations where the planes of parts are in contact and tightly fit together, leaving no gaps between the planes. In other cases, a certain gap needs to be designed between the planes to prevent assembly interference or to ensure that the assembled product dimensions remain within specifications. Generally, as long as it does not affect the product's function and quality, the gap should be as large as possible.</p><h3 dir="ltr">2. Simplify Assembly Relationships</h3><p dir="ltr">Simplifying assembly relationships reduces the number of dimensions in a tolerance chain, thereby decreasing cumulative tolerance. In a dimension chain, fewer dimensions lead to smaller cumulative tolerance. For critical assembly relationships, adjustments should be considered in the initial design phase to simplify assembly and avoid requiring too many parts with strict tolerances, ultimately reducing cumulative tolerance.</p><h3 dir="ltr">3. Use Positioning Features</h3><p dir="ltr">When designing parts with assembling relationships, adding positioning, as illustrated in below. This method enables parts to be accurately assembled into products. In product design, it is only necessary to control the process tolerances of dimensions related to the locating features, allowing looser tolerance requirements for other less critical dimensions.</p><h3 dir="ltr">4. Use Points or Lines for Planar Fits</h3><p dir="ltr">When two parts have a plane-to-plane fit and relative motion, either during assembly or use, a point or line to plane fit can be used instead. This prevents plane deformation or high surface roughness from hindering smooth movement, allowing for more relaxed flatness and surface roughness tolerances.</p><p dir="ltr">The above are some examples of designing appropriate tolerances for CNC machined parts. Want to know more about the biggest myth about tolerances? We’re here to support your project from prototyping to production, whatever the tolerance requirements. RPWORLD provides all your CNC milling and turning needs. We always have manufacturing engineers available to assist with any questions. Ready to start your next project? Contact us now.</p>

Let's discuss a major misunderstanding about CNC machining tolerances.

Reasonable CNC Machining Tolerances - Balancing Precision and Cost

<p id="isPasted">In the complex world of manufacturing, precision and accuracy are paramount. Tolerances play a crucial role in ensuring that parts fit together correctly and function as intended. Whether you are a seasoned manufacturing manager or new to the field, understanding the role of tolerances in product design and machining is essential for optimizing your processes and achieving high-quality results.</p><h2>The Importance of Precision in Manufacturing</h2><p>Precision machining is at the heart of modern manufacturing. It involves the use of advanced equipment and techniques to produce parts that meet exact specifications. The goal is to create components that not only fit together seamlessly but also perform reliably under various conditions.</p><p><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzIyMDE2MzM1NDI1LVByZWNpc2lvbi1NYWNoaW5pbmctQXNzZW1ibHktNzY4eDUxMi5qcGciLCJlZGl0cyI6eyJyZXNpemUiOnsid2lkdGgiOjk1MCwiZml0IjoiY292ZXIifX19" style="width: 100%px;" class="fr-fic fr-dib"></p><h3>What Are Tolerances?</h3><p>In the context of product design and machining, tolerances refer to the permissible limits of variation in a physical dimension. These variations can occur due to factors such as material properties, machining processes, and environmental conditions. Tolerances ensure that even with these variations, the parts will still function correctly and fit together as intended.</p><h3>Types of Tolerances</h3><p>There are several types of tolerances that designers and machinists must consider:</p><ol><li>Dimensional Tolerances: These specify the allowable variation in the dimensions of a part. For example, a shaft may be specified as 50 mm ± 0.02 mm, meaning the actual diameter can vary between 49.98 mm and 50.02 mm.</li><li>Geometric Tolerances: These control the shape, orientation, and position of features on a part. Examples include flatness, cylindricity, and perpendicularity.</li><li>Surface Finish Tolerances: These define the acceptable roughness or smoothness of a surface. Surface finish can impact the performance, appearance, and wear characteristics of a part.</li></ol><h2>The Role of Tolerances in Product Design</h2><p>In product design, tolerances are integral to ensuring that parts can be manufactured consistently and perform as intended. Designers must balance the need for precision with the practicalities of manufacturing capabilities and costs.</p><h3>Balancing Precision and Cost</h3><p>Achieving tighter tolerances often requires more advanced equipment, longer machining times, and higher costs. Therefore, it's crucial to determine the appropriate level of precision for each part based on its function and the overall assembly. Overly tight tolerances can lead to unnecessary expenses, while too loose tolerances can result in parts that don't fit or function properly.</p><h3>Design for Manufacturability (DFM)</h3><p>Design for Manufacturability (DFM) is a design approach that considers the manufacturing process during the design phase. By incorporating DFM principles, designers can create parts that are easier and more cost-effective to produce while still meeting the required tolerances. This involves selecting appropriate materials, designing for efficient machining, and specifying tolerances that align with the capabilities of the manufacturing equipment.</p><p><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzIyMDE2MzE1MTA0LURGTS1CbG9nLUhlYWRlci5wbmciLCJlZGl0cyI6eyJyZXNpemUiOnsid2lkdGgiOjk1MCwiZml0IjoiY292ZXIifX19" style="width: 100%px;" class="fr-fic fr-dib"></p><h2>The Impact of Tolerances on Machining</h2><p>Machining is the process of removing material from a workpiece to achieve the desired shape and dimensions. Tolerances play a significant role in determining the machining process, equipment selection, and quality control measures.</p><h3>Equipment and Technology</h3><p>The choice of machining equipment and technology has a direct impact on the achievable tolerances. Advanced CNC (Computer Numerical Control) machines, such as those offered by <a href="https://www.apsx.com/apsx-machines-compact" target="_blank" rel="noopener noreferrer">APSX Machines</a>, are capable of producing highly precise parts with tight tolerances. These machines use computer-controlled movements to achieve consistent and accurate results, making them ideal for high-precision applications.</p><h3>Quality Control and Inspection</h3><p>To ensure that machined parts meet the specified tolerances, rigorous quality control and inspection processes are essential. This includes using precision measuring tools, such as calipers, micrometers, and coordinate measuring machines (CMMs), to verify the dimensions and geometric features of the parts. Regular calibration of equipment and adherence to quality standards are also critical to maintaining accuracy and consistency.</p><p><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzIyMDE2Mjg5NTkyLTE3MDc5Mjk2NjQ3NDAuanBlZyIsImVkaXRzIjp7InJlc2l6ZSI6eyJ3aWR0aCI6OTUwLCJmaXQiOiJjb3ZlciJ9fX0=" style="width: 100%px;" class="fr-fic fr-dib"></p><h3>Machining Knowledge and Expertise</h3><p>Experienced machinists and engineers bring invaluable knowledge to the table when it comes to achieving precise tolerances. Their understanding of material properties, machining techniques, and equipment capabilities allows them to optimize the process and troubleshoot any issues that arise. Continuous training and staying up-to-date with the latest advancements in machining technology are essential for maintaining high standards of precision.</p><h2>Practical Applications and Examples</h2><p>Understanding tolerances and their impact on product design and machining is not just theoretical; it has practical implications for various industries. Here are a few examples:</p><h3>Aerospace Industry</h3><p>In the aerospace industry, precision and reliability are critical. Components such as turbine blades, landing gear, and structural elements must meet strict tolerances to ensure safety and performance. Advanced machining techniques and rigorous quality control measures are employed to achieve the required precision.</p><h3>Medical Devices</h3><p>Medical devices, such as surgical instruments and implants, require high levels of precision to ensure proper functionality and patient safety. Tolerances play a key role in the design and manufacturing of these devices, with stringent quality standards in place to verify compliance.</p><h3>Automotive Manufacturing</h3><p>In automotive manufacturing, tolerances are essential for ensuring that engine components, transmission parts, and other critical elements fit together correctly and function reliably. Achieving consistent tolerances helps improve the performance and longevity of vehicles.</p><h2>Conclusion</h2><p>Tolerances are a fundamental aspect of product design and machining that impact the quality, performance, and cost of manufactured parts. By understanding the role of tolerances and implementing best practices in design and machining processes, manufacturing managers can optimize productivity and efficiency while delivering high-quality products.</p><p>Embrace precision machining and leverage advanced equipment like <a href="https://www.apsx.com/" target="_blank" rel="noopener noreferrer">APSX Machines</a> to achieve the desired tolerances and elevate your manufacturing operations. Stay informed, invest in the right technology, and continuously improve your processes to remain competitive in today's demanding market.</p><p>Take the next step in optimizing your manufacturing processes by understanding and implementing the principles of tolerances in product design and machining.</p><p>#apsxmachines #precisionmachining #productdesign #designformanufacturability #apsxnano #swisslathe #swisscnc #cncmachining #producttolerance</p>

Whether you are a seasoned manufacturing manager or new to the field, understanding the role of tolerances in product design and machining is essential for optimizing your processes and achieving high-quality results.

Understanding the Role of Tolerances in Product Design and Machining

<p dir="ltr" id="isPasted">When one talks about hybrid manufacturing, they are typically referring to a production approach that combines subtractive manufacturing processes—like CNC machining—and additive manufacturing technologies—such as extrusion 3D printing. With contrasting strengths and weaknesses, these two processes complement each other and integrating them in a hybrid solution can enable manufacturers to exploit the benefits of each production approach while minimizing their limitations.</p><p dir="ltr"><a href="https://www.smartzavod.com/" target="_blank" rel="noopener noreferrer">SmartZavod</a>, a German-Ukrainian startup specializing in industrial production, is bringing to market an innovative hybrid manufacturing solution for polymer materials. While some hybrid approaches rely on two separate systems to execute the additive and subtractive processes, SmartZavod has integrated the two into a single, highly automated system called the SmartZavod GENx. As we’ll see in more depth, this integrated technology enables users to manufacture high-precision parts from a range of polymer materials.</p><h2 dir="ltr">Why Hybrid is Superior</h2><p dir="ltr">Hybrid manufacturing is an increasingly popular production approach because it combines the strengths of 3D printing and CNC machining. In terms of 3D printing, the technology has a number of benefits, including agile production, minimal material waste, the ability to produce customized products, and perhaps above all, design freedom. But it is also limited when it comes to producing parts with exact tolerances and ultra-smooth surface finishes. CNC machining, for its part, is capable of achieving the tightest production tolerances but is associated with significant material wastage and design limitations. Used together, manufacturers can avoid the pitfalls of each technology while benefiting from their capabilities.&nbsp;</p><p dir="ltr">The SmartZavod team, which has to date raised €300k in funding, was quick to see the potential of hybrid manufacturing for polymer part production. With support from academic institutions and industrial partners, the team has worked for the past three years to develop its hybrid manufacturing hardware solution. This highly automated and modular system, which consists of a patented mechatronic platform, was engineered to meet the sustainability goals of Industry 5.0 and is capable of producing complex geometries and multi-material components without generating material waste and minimizing energy usage through its lightweight architecture.</p><p dir="ltr">Like other additive manufacturing solutions, the hybrid system is also well positioned to meet the growing demand for personalized products and even mass customization. Additive manufacturing is a key enabler of scalable customization, as the design of a product does not influence the cost of manufacturing it, as is the case with more conventional production methods, such as injection molding. In other words, the ability to easily adjust 3D designs and print on demand makes personalization possible and efficient.&nbsp;</p><p dir="ltr"><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1721075330118-DemoGif1.jpg" style="width: 100%px;" class="fr-fic fr-dib"></p><h2 dir="ltr">How the GENx System Works</h2><p dir="ltr">SmartZavod’s GENx system is a unique approach to hybrid manufacturing. While some existing systems use a robotic arm to control the additive and subtractive functions, SmartZavod has pioneered a delta setup that is capable of both multi-material polymer 3D printing and high-tolerance CNC machining thanks to a patented tool change system.</p><p dir="ltr">In short, the hybrid system works by first depositing layers of material using a extrusion tool onto the build surface to create a near net shape. From there, the system automatically changes tools, exchanging the print head for a CNC machining tool that precisely trims the edges of the printed layers to meet the correct tolerances of the original CAD design. Both the printhead and machining tool are controlled by a proprietary kinematic moving system, which ensures precise and fast motion and can make the most out of the machine’s available working area (up to 600 x 800 mm).</p><p dir="ltr">Notably, the tool change system that enables the hybrid functionality of the GENx system also enables users to print using multiple materials. According to SmartZavod, the whole system is modular and can be fitted with customized tool sets based on end user needs. The company’s first system, the GEN1, can be fitted with three tools (i.e. the Dyze Design Pro, Dyze Design Typhoon, and Mechatron High Speed Spindle) and three axes, however a customized system can have up to six tool positions and six working axes. Tools can include the aforementioned extruders and spindle as well as dosing and mixing tools for printing compounds, spraying tools for applying coatings, and measuring touch sensors for further automating quality control assessments.</p><p dir="ltr">When the 3D print is completed and the required tolerances and features have been achieved thanks to the subtractive machining process, the GENx system is equipped with an automated part removal system. This feature uses a carbon-based printing surface and segmented heating zones so that parts detach automatically without the need for any prying or cutting off the build plate. As any maker or 3D printer user will know, this small automation can save a ton of time and energy.&nbsp;</p><p dir="ltr">Built for industrial applications, SmartZavod’s hybrid solution is compatible with a wide range of materials, including engineering-grade polymers, composites, silicones, and ceramics. This wide material variety is possible thanks to the printhead’s ability to reach extrusion temperatures of up to 500 °C. As mentioned, these materials can be combined in a single print for a wider array of part functionalities.</p><h2 dir="ltr">Hybrid Manufacturing in Action</h2><p dir="ltr">SmartZavod’s hybrid manufacturing solution has a wide range of potential applications that can transform how products are made. At present, the company is in the final stages of system development (according to the Technology Readiness Levels system, the company is at least at stage seven out of nine) and is seeking more use case partners for its platform. In parallel, the company is also raising €1.5 million to further advance and commercialize its solution.</p><p dir="ltr">For now and the foreseeable future, SmartZavod is aiming to make its technology more accessible to customers through a service business model. For example, the hybrid 3D printer could be installed in university labs or innovation hubs, where startups and small-to-medium-sized businesses could order parts via a web platform. “This way, businesses can get access to advanced technology without the need to invest in equipment,” <a href="https://easyengineering.eu/smartzavod-next-gen-of-hybrid-manufacturing/" target="_blank">said</a> Oleksii Solntsev, SmartZavod CEO.</p><p dir="ltr">The innovative startup and its technology have already participated in three pilot projects in partnership with OSV LLC Poland, the Manufacturing Innovation Valley in Lithuania, and the children’s clinic Kyiv. The pilot project with OSV LLC<a href="https://www.osv.com.ua/en/" target="_blank">OSV LLC</a>, a small-series manufacturer from Poland specialized in manufacturing mixing and dosing equipment for polyurethanes and silicones, consisted of producing a two-part component for a dosing-mixing system. The main component, traditionally made from aluminum, was printed from PA 6 and post-processed on the spot using SmartZavod’s integrated hybrid solution. From there, a third tool was used to print a silicone seal on top of the PA 6 print, and the finished part was removed automatically from the build surface.&nbsp;</p><p dir="ltr">In the end, SmartZavod’s technology offered OSV several benefits, including 50% reduction in cost per part, 70% less labor time, 30% lower labor costs, as well as minimized energy consumption and material waste, all while meeting the specifications of the original part. This partnership was organized through the Horizon 2020 funding program.</p><h2 dir="ltr">Collaboration Opportunities</h2><p dir="ltr">In addition to startups and small manufacturing businesses, SmartZavod is also interested in targeting larger manufacturing enterprises as clients, as they could benefit from its flexible and highly automated hybrid production. For instance, the company is currently working on use cases with two major manufacturers.</p><p dir="ltr">“We communicate with potential customers, study their requests, create the necessary products in-house, send them for testing, receive feedback, and improve the model,” Oleksii <a href="https://www.smartzavod.com/releases/how-did-smartzavod-transform-the-hybrid-technology-of-industry-5-0/" target="_blank">explained in a recent interview</a>. “Our potential customers currently include two large manufacturing companies, ten medium-sized ones, and five small ones. In the near future, we aim to engage in five solid use cases, which we anticipate will enable our transition to TRL 8 and facilitate our first sales, especially through agreements with customers already participating in pilot programs with SmartZavod.”</p><p dir="ltr">In sum, SmartZavod is continually improving its hardware solution based on user feedback to enhance the system process and performance. As the young company advances towards the full maturation of its solution, it aims to be a key player in the ushering in of Industry 5.0, which places an increasingly important focus on sustainability and societal value.&nbsp;</p><p dir="ltr"><a href="https://www.smartzavod.com/" target="_blank" rel="noopener noreferrer">Get in touch with them via their website here.</a></p>

SmartZavod’s automated hybrid technology combines polymer additive manufacturing and CNC machining for high-quality functional parts.


Hybrid Manufacturing Takes Polymer Part Production to the Next Level

<p id="isPasted">Ever since its inception, metal additive manufacturing has caught the attention of engineers and tech enthusiasts for its unconventional bottom-up approach and the buzz surrounding what it is capable of. Is it really advantageous to use additive manufacturing for a part that’s been reliably produced through subtractive processes for years? This article discusses this question and points out cases when <a href="https://xometry.eu/en/direct-metal-laser-sintering/" target="_blank" rel="noreferrer noopener">metal 3D printing</a> can be a good choice for the production of parts and when not.</p><h2 data-counter-attr="value0"><strong>Metal 3D Printing (DMLS): Process Overview</strong></h2><p>Conventional manufacturing technologies like CNC machining are normally subtractive processes which means it removes material in order to shape a product whereas metal 3D printing technology is additive. One of the most common and popular metal 3D printing technologies is <a href="https://xometry.eu/en/direct-metal-laser-sintering/" target="_blank" rel="noreferrer noopener">direct metal laser sintering (DMLS)</a>.</p><p><span contenteditable="false" draggable="true" class="fr-video fr-deletable fr-fvc fr-dvb fr-draggable"><iframe width="640" height="360" src="https://www.youtube.com/embed/FxzFzbi0wF4?&amp;wmode=opaque&amp;enablejsapi=1&amp;origin=https://www.wevolver.com" frameborder="0" allowfullscreen="" class="fr-draggable" data-lf-form-tracking-inspected-kn9eq4roawkarlvp="true" data-lf-yt-playback-inspected-kn9eq4roawkarlvp="true" data-lf-vimeo-playback-inspected-kn9eq4roawkarlvp="true"></iframe></span><br></p><p>The typical DMLS process begins by slicing the 3D design CAD file data into extremely thin layers, effectively generating a 2D model for each layer.</p><p>The machine uses a high-powered optic laser. Inside the build chamber area, there is a material dispensing platform and a build platform along with a roller used to move new powder over the build platform. The technology fuses metal powder into a solid part by melting it locally using the focused laser beam. Parts are built up additively layer by layer.</p><h2 data-counter-attr="value1"><strong>Cases When to Choose Metal 3D Printing</strong></h2><p>Metal 3D printing comes with its own set of advantages over traditional machining. We listed here a few cases when it is worth considering metal 3D printing over <a href="https://xometry.eu/en/cnc-machining/" target="_blank" rel="noreferrer noopener">CNC machining</a>.</p><h3 data-counter-attr="value2"><strong>Your Design is Complex</strong></h3><p>When it comes to design complexity and freedom, metal 3D printing has a huge edge over conventional. Many complex designs cannot be manufactured with conventional technologies with as much ease as with 3D printing.</p><p>Another advantage here is the low cost of complexity. Creating complex mechanical parts via traditional manufacturing requires precision and skills, especially for the assembly of complex parts, which means that price increases with complexity. It is not the case with 3D printing, which creates an entire piece in one process, instead of creating each component before assembling. Therefore, there is no added cost for complexity.</p><h3 data-counter-attr="value3"><strong>You Urgently Need Metal Prototypes</strong></h3><p>If the number of parts required is less, say 1 to 5 or so or for prototyping, metal AM is much more advantageous. Since the cost is almost the same for each added unit, it is possible to make a needed amount of changes to the part. It can be used for prototyping: you’d use 3D printing to make a prototype and update the prototype until the required features are met. This is a crucial step before getting the product to mass production. It can also be used during the rest of the manufacturing process, to create unique pieces that can be more responsive to your needs.</p><p>Also, it can be faster to get metal 3D prints rather than CNC machined parts. CNC machining normally requires more time to stock materials, set up the machine, get the right tooling. As a result, it can take several weeks to have the first part in hand. For 3D printing, even for DMLS which is more complex than traditional ones, the part can be printed on demand and shipped without any ramp ­up or tooling, resulting in shorter lead time compared to conventional technologies. The combination of the reduced lead time and the more efficient prototyping process reduces the turnaround time. This is one of the biggest advantages of metal 3D printing.</p><h3 data-counter-attr="value4"><strong>You Want Lightweight and Durable Components</strong></h3><p>Aerospace and medical industries naturally require lightweight yet durable parts. Super alloys like Inconel 718, AlSi10Mg, Cobalt-chromium are known to be lightweight compared to their conventionally machined counterparts. Manufacturing a part with these alloys naturally makes them lightweight comparatively. As an example, GE’s renowned 3D printed fuel nozzles for its LEAP family of engines used to be made from 20 discrete parts coming from independent suppliers but using direct metal laser sintering (DMLS) resulted in a single-piece component that’s 25 per cent lighter and five times stronger than the original parts.</p><p><span class="fr-img-caption fr-fic fr-dib" style="width: 790px;"><span class="fr-img-wrap"><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzIwNjAwNjgxODc3LUFNX05venpsZS53ZWJwIiwiZWRpdHMiOnsicmVzaXplIjp7IndpZHRoIjo5NTAsImZpdCI6ImNvdmVyIn19fQ==" style="width: 100%px;" class="fr-fic fr-dib"><span class="fr-inner">Fuel nozzle (Source: GE)</span></span></span></p><h3 data-counter-attr="value5" id="isPasted"><strong>You’d Like to Avoid Wastage of Material</strong></h3><p>3D printing is incredibly resource ­efficient since the only material consumed is what passes under the laser (or through the extruder, etc.), whereas traditional CNC machining leaves chips and small pieces of metal that should be recycled. The fact that manufacturers don’t have to produce as much of a given product to justify the setup costs also reduces waste.&nbsp;</p><h2 data-counter-attr="value6"><strong>Disadvantages of Choosing Metal 3D Printing</strong></h2><p>Apart from the advantages metal 3D printing possess over conventional technologies, there are a few considerations where preferring the latter is advised.</p><h3 data-counter-attr="value7"><strong>Grainy Surface Finish</strong></h3><p>3D printing is an additive process, which means surfaces won’t be as smooth as with <a href="https://xometry.eu/en/cnc-machining/" target="_blank" rel="noreferrer noopener">CNC machining</a>, and that it won’t be as easy to produce the desired surface textures. So if the surface texture is important for you, CNC machining should be considered instead. Nevertheless, there are many post-processing techniques that are available to remove support structures, enhance the finish and improve the aesthetics, the cost also increases accordingly.</p><p><span class="fr-img-caption fr-fic fr-dib" style="width: 790px;"><span class="fr-img-wrap"><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzIwNjAwNzEwOTQ1LUdyYWlueS1zdHJ1Y3R1cmUtb2YtbWV0YWwtM0QtcHJpbnRpbmcud2VicCIsImVkaXRzIjp7InJlc2l6ZSI6eyJ3aWR0aCI6OTUwLCJmaXQiOiJjb3ZlciJ9fX0=" style="width: 100%px;" class="fr-fic fr-dib"><span class="fr-inner">Grainy structure of metal 3D printing</span></span></span></p><h3 data-counter-attr="value8" id="isPasted"><strong>Less Strong Parts</strong></h3><p>Because of the additive technology itself, metal 3D printed parts cannot be as strong as the one machined out of a solid metal block. The final strength depends on the design, size and material, but in general compressive strength of metal 3D prints is on average 40-50% lower than of CNC machined parts.</p><h3 data-counter-attr="value9"><strong>Expensive Serial Production&nbsp;</strong></h3><p>It becomes cheaper to mass-produce through CNC machining. Mass production is still a huge deciding factor across the industries and this is where 3D printing lags behind and the speed at which a 3D printer can assemble an object often pales in comparison to the traditional assembly line.</p><h3 data-counter-attr="value10"><strong>Limited Build Volume</strong></h3><p>When a large part size is required, it’s always better to go with CNC machining. For instance, the maximum part size that is achieved with DMLS is 250 x 250 x 325 mm and for <a href="https://xometry.eu/en/cnc-machining/" target="_blank" rel="noreferrer noopener">CNC machining</a>, it is 2000 x 800 x 1000 mm. The size comparison clearly shows the inability of 3D printing in manufacturing huge parts due to its limited powder bed size.&nbsp;</p><h3 data-counter-attr="value11"><strong>Limited Material Selection</strong></h3><p>Conventional manufacturing options like injection moulding and CNC machining can offer a high material selection. When it comes to metal 3D printing, the material selection is lower, which can be a limiting factor when specific materials are needed for the required part and must be taken into consideration when deciding which technical properties you want your product to have. As of now at Xometry we have five metal/alloy powders that support DMLS whereas if the required part needs some other material, there is no other option apart from traditional machining processes.</p><h2 data-counter-attr="value12"><strong>Summary</strong></h2><p>It cannot be said that metal 3D printing replaces traditional manufacturing technologies in all aspects as both of these have their own set of advantages where they shine and disadvantages where they don’t. Here is a brief summary of what are the strengths of both technologies:</p><table><thead><tr><th>Metal 3D Printing</th><th>CNC Machining</th></tr></thead><tbody><tr><td contenteditable="true">Quicker turnaround</td><td contenteditable="true">Mass production</td></tr><tr><td contenteditable="true">Prototyping and low volume production</td><td contenteditable="true">Solid surface structure</td></tr><tr><td contenteditable="true">Ease of achieving complex designs</td><td contenteditable="true">Use of materials and need for technical characteristics unavailable with 3D printing</td></tr><tr><td contenteditable="true">Reduced waste</td><td contenteditable="true">Large-sized parts</td></tr><tr><td contenteditable="true">Customization and adaptability</td><td contenteditable="true">Strong parts</td></tr></tbody></table>

Metal 3D printing: 4 cases when to choose it over CNC machining and when not.

Technology Overview: When You Should Really Go for Metal 3D Printing

<p id="isPasted">Build strength into your part design by incorporating strategic support features and selecting the right thermoplastics</p><p>Product designers build strength into their&nbsp;<a href="https://www.protolabs.com/en-gb/services/injection-moulding/" target="_blank" rel="noopener noreferrer">injection-moulded</a> parts in different ways and for different reasons. Dissecting part application is a good first step in determining if additional strength should get designed into a part. How will customers be using your product and what environment will it live in? You may need parts that can withstand repetitive impact, resist wear, or bear heavy loads. It may be as simple as integrating ribs or gussets into your design, or a more complicated combination of design elements involving support features, material, wall thickness, and more. Finding the proper balance of design considerations will help address your part’s need for strength and stability.</p><p><strong>Ribs and Gussets</strong></p><p>Ribs are thin, wall-like features typically designed into the geometry of a part to add internal support to walls or other features like bosses. In a similar fashion, gussets are support features that reinforce areas such as walls or bosses to the floor. Just as bridge beams and columns are supported at their vertex with gussets to add critical strength to the structure, the same concept applies to plastic injection moulding.</p><p><br></p><p><img width="570" src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzE5MzA5NzAyNTcxLTE3MTkzMDk3MDI1NzEucG5nIiwiZWRpdHMiOnsicmVzaXplIjp7IndpZHRoIjo5NTAsImZpdCI6ImNvdmVyIn19fQ==" class="fr-fic fr-dii" style="width: 404px;"></p><p><br></p><p>Our design cube illustrates thick and thin ribs, proper use of gussets, well-designed bosses, and other considerations to be mindful of when building strength into parts.*</p><p>Both ribs and gussets provide stability in parts without having to increase wall thickness, and are particularly beneficial for parts with already thin walls that could potentially be compromised by end user wear and tear. It’s important to note that ribs and gussets should be no more than 60 percent of nominal wall thickness. These features are kept thinner than the primary walls in an effort to avoid overly thick sections where ribs and gussets intersect with the wall. When you have a surplus of material meeting at internal rib-to-wall intersections, sink marks can appear on the visible side of the part.</p><p>Product designers can play with different ribbed formations to create square, rectangle, diamond, triangle, or honeycomb patterns that stiffen the part. A pattern of ribs is equivalent to coring out unneeded material, leaving only the rib support system—it also reduces the weight and cost of the part. But, remember to not remove surfaces and features that interface with the other parts in the product assembly.</p><p><strong>Fillets</strong></p><p>Because sharp corners weaken parts, fillets—curved faces where ribs meet walls—can also be designed into part geometry to eliminate additional mechanical stress concentrations on a finished part. Much like gussets, a fillet that is too small will fail to accomplish its task of stress reduction, but a fillet that is too large can once again create sink. Identifying the proper size and locations of fillets (and ribs and gussets) are important. When adding a fillet to the inside of a corner, also add a radius to the outside of the corner, if possible. If the risk of sink is too high in some sections, then other strength-building methods should be considered.</p><p><strong>Thermoplastics</strong></p><p>Material selection also plays a role in the stiffness, durability, toughness and other characteristics of parts; balancing the relationship between those material properties and part functionality is key. For example, product designers can choose a thermoplastic resin that will make a stiff, rigid part, but if its application demands a high degree of impact resistance, the brittleness of an inflexible part may cause it to break. Material properties differ from resin to resin—here’s a glance at some of our more frequently used resins,</p><p>ABS is a good, stable consumer-grade resin that is tough and impact-resistant in daily use environments. It’s commonly used in housings for remote controls, battery-powered tools, and body panels for monitors, printers, and copiers. There may be chemical resistance concerns with ABS.</p><p>Polycarbonate is more impact-resistant than ABS, and good for lenses and parts that require more shine. It is susceptible to stress cracking, and risks crazing/hazing due to chemical compatibility concerns.</p><p>Unfilled nylon is pliable and impact-resistant with good lubricity for wear. Glass-fibre filler increases nylon’s stiffness and compressive strength, but the material becomes more brittle on impact. Glass-fibre filler helps increase heat deflection.</p><p>Acetal is an excellent self-lubricating bearing material with great wear properties and good stiffness. It’s not good for cosmetic parts or parts that require pad printing, paint or decals.</p><p>TPEs are great for dust seals and padding corners for impact resistance, and used in overmoulding applications for grip features. They’re not always good in dynamic applications; static applications are best. There may be chemical resistance concerns with TPE.</p><p>Reinforcing materials with an additive can also build strength into parts. Long and short glass fibres make resins stronger and stiffer (but more brittle), and carbon fibres can make resins even stiffer yet. Minerals such as talc and clay are often used as fillers to increase the hardness of finished parts; and glass beads and mica flakes are used to stiffen a part and reduce warping and shrink.</p><p><strong>Wall Thickness</strong></p><p>Sometimes, if you want to add strength to a part, you just have to increase overall wall thickness. Protolabs provides a list of recommended wall thicknesses based on resin type to help design parts that are neither too thin nor too thick. The larger that parts get, the more attention needs to be paid to ribs, gussets, materials, and other factors that improve strength. As usual, our applications engineers are available to discuss part geometry and design, and look for the interactive mouldability analysis that comes with every quoted part at Protolabs.</p><p><a href="https://explore.protolabs.com/design-cube/" target="_blank" rel="noopener noreferrer">Request a free injection moulding design cube!</a></p>

Build strength into your part design by incorporating strategic support features and selecting the right thermoplastics.

How to Reinforce Parts with Support Features and Durable Materials

<p>Fillets and chamfers are usually added to solid models to make them look good and eliminate sharp edges and corners. Many engineers use these features with ease in their CAD models in order to improve the features and elevate the designs. But what is the impact of fillets and chamfers on CNC machining costs?</p><p id="isPasted">These fillets and chamfers are aesthetically pleasing and add up value to the design. But they also increase the machine time and the cost of CNC machining projects significantly.</p><p>The primary questions to be considered before adding a fillet or chamfer to the design are:</p><ul><li>What is the main function of the fillet or chamfer?</li><li>Is this fillet or chamfer really necessary for the part to function?</li><li>How cost-effective is it to add this feature for the quantity I’m producing?</li><li>How can the tolerance be checked?</li></ul><p>For a better understanding of why these design and cost considerations are important, let’s walk through some examples.</p><h2 data-counter-attr="value0"><strong>Why Fillets and Chamfers Increase Machining Costs</strong></h2><h3 data-counter-attr="value1"><strong>Setting Up the Tools is Time-consuming and Expensive</strong></h3><p>Initially, let’s compare how fillets and chamfers are done with the CNC machining process. Chamfers are usually made with a tool that is ground to the correct angle, such as a countersink, chamfer tool or a spot drill.</p><p>A chamfer tool is used to make exterior ones, while a spot drill or countersink tool is used to make interior chamfers.</p><p><span class="fr-img-caption fr-fic fr-dib" style="width: 790px;"><span class="fr-img-wrap"><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1718326401123-countersinks-for-chamfers.webp" style="width: 100%px;" class="fr-fic fr-dib"><span class="fr-inner">Countersinks for CNC machines</span></span></span></p><p id="isPasted">Fillets are created with an end mill that machines the part profile. If the fillet is along a part edge, a corner rounding end mill is likely to be employed.&nbsp;</p><p>However, setting up these tools can be quite time-consuming and expensive. The cutter must blend the radius into the part’s top and side faces so that there are no errors and no steps remaining.</p><p>In order to achieve this, the fillets along part edges (like the green fillet in <strong>Figure 1</strong>) are typically made with a ball-nose end mill. To achieve a high-quality fillet, the cutter is programmed to closely follow the part edge and make very small step-overs.</p><p>But this makes the process expensive. Including more fillets and chamfers with high precision and quality increases the machining time significantly. In a machining environment, time is money. Hence, prior to adding an extra fillet or chamfer, consider if it is required for the part’s function and worth the extra costs.</p><p><span class="fr-img-caption fr-fic fr-dib" style="width: 790px;"><span class="fr-img-wrap"><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1718326421004-image.webp" style="width: 100%px;" class="fr-fic fr-dib"><span class="fr-inner">Figure 1</span></span></span></p><p><span class="fr-img-caption fr-fic fr-dib" style="width: 790px;"><span class="fr-img-wrap"><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1718326435822-ball-nose-mills-for-fillets.webp" style="width: 100%px;" class="fr-fic fr-dib"><span class="fr-inner">Ball nose mills for CNC machines</span></span></span></p><h3 data-counter-attr="value2" id="isPasted"><strong>Fillets and Chamfers Are Not Well-suited for Low Production Volume</strong></h3><p>Production volume is another major factor that increases costs. Machining cost is inversely proportional to the parts produced and hence, low parts production means higher costs and vice versa.</p><p>Moreover, adding fillets and chamfers above that low quantity increases the overall cost (see the table with cost comparison below). A large production run might be using a casting or forging process. In this case, the fillet would not only be cost-effective comparatively but also necessary.</p><h2 data-counter-attr="value3"><strong>How to Reduce Machining Costs With Fillets and Chamfers</strong></h2><p>On evaluating those factors and deciding to add a fillet or chamfer, the next step is to consider how to machine the part at a low expense.</p><h3 data-counter-attr="value4"><strong>Design Chamfers With the Right Tolerances</strong></h3><p>In <strong>Figure 2</strong> below, the blue hole on the top of this part is a M18 X 2 tapped hole with a 0.635mm chamfer. This chamfer is necessary because it enables the fastener to start more easily into the hole.</p><p><span class="fr-img-caption fr-fic fr-dib" style="width: 790px;"><span class="fr-img-wrap"><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1718326455649-image-1.webp" style="width: 100%px;" class="fr-fic fr-dib"><span class="fr-inner">Figure 2</span></span></span></p><p id="isPasted">When designing a chamfer like the one above, tolerances shouldn’t be ignored. The tighter the tolerance, the costlier the part.</p><p>In the example shown in <strong>Figure 2</strong>, the chamfer diameter is noted to three decimal places, which means that the diameter of the chamfer can only deviate ± 0.127mm the nominal size.</p><p>A tighter tolerance would in turn increase the costs as it needs to be checked more frequently and technically a chamfer gauge would be needed for a three decimal place accuracy. Naturally, with more scrutiny and tougher measurement, the parts get more expensive.</p><p>Instead, if the chamfer is changed to two decimal places for accuracy, the allowable deviation would be doubled to ± 0.254mm the nominal size. This would allow you to check less frequently and use a vernier calliper instead of a chamfer gauge. If this small adjustment can be acceptable by the design, the costs can also be reduced.</p><h3 data-counter-attr="value5"><strong>Remove Chamfers When Possible</strong></h3><p>Removing chamfers from the hole callout can also be considered to make things less expensive and simpler (see the table below).&nbsp;</p><p>For example, in <strong>Figure 3</strong>, the prime function of the chamfers in the side grey holes is to facilitate the easier assembly of the pin into each hole. If the exact size isn’t critical, you could leave the chamfer feature off the solid model and add a note to the drawing stating to “remove all sharp edges.” Alternatively, it could be called out with a minimum and maximum feature size and generous tolerance as shown in <strong>Figure 3</strong>.</p><p><span class="fr-img-caption fr-fic fr-dib" style="width: 790px;"><span class="fr-img-wrap"><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1718326474402-image-2.webp" style="width: 100%px;" class="fr-fic fr-dib"><span class="fr-inner">Figure 3</span></span></span></p><h3 data-counter-attr="value6" id="isPasted"><strong>Use Chamfers Instead of Fillets When Possible</strong></h3><p>If the design allows for swapping of chamfers for fillet, it is ideal for making the part cheaper. For example, chamfers along the part edges, like the red chamfer, are much easier and more affordable than fillets.</p><p>It takes more time to set up a fillet radius tool than a chamfer tool as the tool designer has to take care that it blends with the surfaces that are joined by a fillet. In order to achieve the intended accuracy and precision, the ball nose end mill needs to pass multiple times along the fillet region.</p><p>Since a chamfer tool needs less time to set up and operate, it reduces the cost compared to a fillet.</p><p>If a fillet is necessary and chamfer isn’t an option, try making a standard size if you are able to use a radius milling cutter. Standard radius cutters start at 1.6mm and increase by 0.8mm. Machining a fillet with this tool is always faster than using a ball-nose end mill.</p><p>The below table explains the cost variations according to the features, comparing CNC machining costs for 1, 10 and 100 parts.</p><table id="isPasted"><thead><tr><th>3D model</th><th>Cost per 1 part</th><th>Cost per 10 parts</th><th>Cost per 100 parts</th></tr></thead><tbody><tr><td><p><br></p><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1718326493921-1718326493921.png" alt="3D model representing a part with fillets and chamfers" width="300" height="169" srcset="https://xometry.pro/wp-content/uploads/2023/09/image-300x169.png 300w, https://xometry.pro/wp-content/uploads/2023/09/image.png 398w" sizes="(max-width: 300px) 100vw, 300px" class="fr-fic fr-dii"><p>With both fillets and chamfers</p></td><td>€449.81</td><td>€146.93</td><td>€58.96</td></tr><tr><td><p><br></p><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1718326493833-1718326493833.png" alt="Model with fillets" width="300" height="198" srcset="https://xometry.pro/wp-content/uploads/2023/09/model-with-fillets-300x198.png 300w, https://xometry.pro/wp-content/uploads/2023/09/model-with-fillets.png 650w" sizes="(max-width: 300px) 100vw, 300px" class="fr-fic fr-dii"><p>With fillets only</p></td><td>€436.60 (-3%)*</td><td>€143.84 (-2%)*</td><td>€57.92 (-2%)*</td></tr><tr><td><p><br></p><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1718326493814-1718326493814.png" alt="Model with chamfers" width="300" height="197" srcset="https://xometry.pro/wp-content/uploads/2023/09/model-with-chamfers-300x197.png 300w, https://xometry.pro/wp-content/uploads/2023/09/model-with-chamfers.png 652w" sizes="(max-width: 300px) 100vw, 300px" class="fr-fic fr-dii"><p>With chamfers only</p></td><td>€436.15 (-3%)*</td><td>€143.72 (-2%)*</td><td>€56.98 (-3%)*</td></tr><tr><td><p><br></p><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1718326493938-1718326493938.png" alt="Model without features" width="300" height="201" srcset="https://xometry.pro/wp-content/uploads/2023/09/model-without-features-300x201.png 300w, https://xometry.pro/wp-content/uploads/2023/09/model-without-features.png 654w" sizes="(max-width: 300px) 100vw, 300px" class="fr-fic fr-dii"><p>Without any features</p></td><td>€400.13 (-11%)*</td><td>€133.99 (-9%)*</td><td>€54.86 (-7%)*</td></tr></tbody></table><p><em>*Compared to the price with fillets and chamfers</em></p><h2 data-counter-attr="value7" id="isPasted"><strong>Use Online Resources to Improve Manufacturability</strong></h2><p>Understanding and estimating how the design decisions, such as adding fillets and chamfers, affect machining time and costs takes some practice and experience.&nbsp;</p><p>But with a plethora of design tips for CNC machining available online, you can gain a head start on improving your design and skill.</p>

Fillets and chamfers are usually added to solid models to make them look good and eliminate sharp edges and corners. Many engineers use these features with ease in their CAD models in order to improve the features and elevate the designs. But what is the impact of fillets and chamfers on CNC costs?

CNC Machining

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