Understanding the role of programmable automation in the field of industrial applications, its architecture, implementations, benefits, and standing amongst other types of industrial automation techniques.

What is Programmable Automation

Joined by Adam Tipper, Managing Director and Co-owner at Next Gen Makers, our host Alex Edwards seeks to explore the experiences faced by apprentices and the best practices companies can deliver to retain young talent and rebuild the engineering workforce.

Manufacturing Apprenticeships: How can we rebuild the workforce?

<p id="isPasted"><a href="https://xometry.eu/en/cnc-machining/" target="_blank" rel="noreferrer noopener">CNC machining</a> is a versatile and precise manufacturing process capable of producing components with a wide range of complexity and sizes using various materials. However, it does come with size limitations dictated by various factors. Awareness of these constraints is crucial for optimising designs and ensuring that designs can be manufactured.</p><h2 data-counter-attr="value0"><strong>General Size Limitations of CNC Machining</strong></h2><p>This section highlights several design tips and considerations that could improve part manufacturability while optimising cost and lead time. It discusses part complexity and CNC manufacturing constraints such as fillets, holes, pockets, threads, and undercuts.</p><h3 data-counter-attr="value1"><strong>Material Blank Size</strong></h3><p>This refers to the size of the raw material used to create the finished part. Material blanks typically need to be slightly larger than the finished part’s measurements to allow for variations and to cut away rough faces of the raw material.&nbsp;</p><p>For example, if the final dimensions are to be 50 x 50 x 50 mm, then a suitable material blank would be roughly 53 x 53 x 53 mm. When designing, take this into consideration by adding additional X, Y, and Z dimensions to your part and matching it to the part size limits below.</p><p><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1732514482046-blank-size-1.png" style="width: 100%px;" class="fr-fic fr-dib"></p><h3 data-counter-attr="value2" id="isPasted"><strong>Limitation for Milled, Lathe and Drilled Parts</strong></h3><table><thead><tr><th>Part/Feature</th><th>CNC Milling</th><th>CNC Turning</th><th>CNC Drilling</th></tr></thead><tbody><tr><td><strong>Maximum size</strong></td><td>The largest CNC milling machines, like the <a href="https://www.k-mm.com/large-machining/" target="_blank" rel="noopener">SNK HF-7VM vertical gantry mill</a>, have a pallet size of 3500 mm by 10000 mm, with X-axis travel of 11000 mm, Y-axis travel of 4700 mm, and Z-axis travel of 2450 mm.</td><td>The largest CNC turning centres, such as the SL 603, can handle parts with diameters up to 930 mm and lengths up to 4000 mm.</td><td>The largest CNC drilling machines, like the <a href="https://www.voortman.net/en/products/v200-plate-drilling-machine" target="_blank" rel="noopener">Voortman V200</a>, can handle plates up to 2400 mm in length, 1000 mm in width, and 60 mm in thickness, with a maximum weight of 600 kg.</td></tr><tr><td><strong>Minimum size</strong></td><td>Typically, the smallest feasible feature size is 0.5 mm. For practical purposes, machining features smaller than 2.5 mm in diameter is considered micro-machining and is generally avoided unless necessary.</td><td>The smallest practical diameter for turned parts is approximately 0.5 mm, with common practice starting from about 1 mm.</td><td>Standard practice for most drilling applications starts at 2.5 mm diameter for ease of production and accuracy. Although, the smallest standard drill bit size used is around 1 mm. For very small features, holes as small as 0.05 mm (50 micrometers) can be drilled, but this falls into the realm of micro-drilling, which requires specialised equipment and techniques.</td></tr><tr><td><strong>Better alternatives for larger parts (than maximum)</strong></td><td>• Injection molding (plastics)<br>• Die casting, metal extrusion (metals)</td><td>• Injection molding (plastics)<br>• Forging, casting (metals)</td><td>–</td></tr><tr><td><strong>Better alternatives for smaller parts (than minimum)</strong></td><td>• Injection molding, micro injection molding, 3D printing, micro machining (plastics)<br>• Micro machining, electroforming, laser cutting, micro EDM, metal injection molding (metals)</td><td>• Injection molding, micro injection molding, 3D printing, micro machining (plastics)<br>• Micro machining, electroforming, laser cutting, micro EDM, metal injection molding (metals)</td><td>–</td></tr></tbody></table><h3 data-counter-attr="value3"><strong>Feature Size Limitations: Reference Chart</strong></h3><p>The following chart summarises the design guidelines associated with various features that can be made using CNC. Its purpose is to help designers optimise components for manufacturability.</p><p><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1732514529304-diagram-cnc-machining-design-guidelines-1.webp" style="width: 100%px;" class="fr-fic fr-dib"></p><p><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1732514573679-chart-cnc-machining-design-guidelines.webp" style="width: 100%px;" class="fr-fic fr-dib"></p><h3 data-counter-attr="value4" id="isPasted"><strong>Size Limitations for Post-Processing</strong></h3><p>The different post processing operations that can be carried out on a part depend on the size of the part. For example, larger parts often do not fit in media-blasting cabinets, therefore such parts cannot be blasted. Another example is that custom racking may be required for parts larger than 3 meters that need to be anodized, electroplated or powder coated.</p><table><thead><tr><th>Process</th><th>Maximum part size&nbsp;</th><th>Notes</th></tr></thead><tbody><tr><td>CNC Turning</td><td>Diameter up to 500 mm and length up to 4500 mm</td><td>Xometry uses specialized tooling, including standard 2-axis lathes, live tooling systems, multi-spindle machines, and Swiss lathes, to produce parts with milled or intricate features.</td></tr><tr><td>CNC Milling</td><td>Xometry’s partner network can typically mill parts up to X-2000 mm, Y-750 mm, and Z-600 mm.</td><td>If your part exceeds 600 mm in machinable height, it will require specialized tooling and an additional manual review for manufacturability.</td></tr><tr><td>CNC Drilling</td><td>Equipment includes upright, bench, and radial drill presses, enabling Xometry to drill holes up to 7 cm in diameter in simple and complex patterns.</td><td>The complexity of the drilling pattern and material may affect lead times and costs.</td></tr></tbody></table><h3 data-counter-attr="value5"><strong>General Manufacturing Standards</strong></h3><p>Unless otherwise specified, Xometry manufactures CNC-machined components to the following standards:</p><ul><li><strong>Surface Finish</strong>: The as-machined surface finish is Ra 3.2 or better, with CNC machine tool marks possibly leaving a swirl-like pattern.</li><li><strong>Edge Treatment</strong>: Sharp edges will be broken and deburred by default. If critical edges need to remain sharp, this should be noted and specified on the CAD drawing.</li><li><strong>Plastic Components</strong>: Clear or transparent plastics will have a matte finish or translucent swirl marks on any machined face. Bead blasting will result in a frosted finish on clear plastics.</li><li><strong>Tolerances</strong>: Tolerances on foam or similar compressible materials cannot be guaranteed.</li></ul><h3 data-counter-attr="value6"><strong>General Tolerances</strong></h3><p>Unless specifically specified by the designer, Xometry will adhere to the industry standard ISO 2768 and ISO 286 tolerances listed below:</p><p><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1732514609862-cnc-machining-tolerances-2048x867.webp" style="width: 100%px;" class="fr-fic fr-dib"></p><p id="isPasted">General tolerances for CNC machining start at ±0.1 mm. Tighter tolerances, defined as smaller than the general standard, can be achieved with CNC machining, reaching up to ±0.01 mm.&nbsp;</p><p>Specialized setups and additional operations like reaming and grinding can allow for even tighter tolerances depending on the material and part geometry. Geometric tolerances (GD&amp;T) can be applied to the drawing, but these may increase inspection times due to the necessary tools and time for checking.</p><p>While tighter tolerances improve a part’s form, fit, and function, they have drawbacks. They can lead to higher scrap rates, additional fixturing, special measurement tools, and longer cycle times from slower cutting speeds. These factors can increase pricing and lead times. Depending on the tolerance and geometry, the part cost can more than double compared to a standard tolerance.</p><h2 data-counter-attr="value7"><strong>General Size Limitations of CNC Machines</strong></h2><p>The physical dimensions of CNC machines’ work envelopes are the main factor limiting their part size capabilities. This constraint affects all types of CNC machines, including turning, milling, and drilling. Other limiting factors include the machine’s axis travel and the number of axes.</p><h3 data-counter-attr="value8"><strong>CNC Machining Work Envelope</strong></h3><p>The CNC machining work envelope refers to the 3D space within which the machine operates. Different machines each have their own work envelope, which limits the size of components that can be manufactured using the machine.&nbsp;</p><p>The physical size of the machine, and more specifically, the X, Y, and Z directions in which the machine can move, dictates the work envelope.</p><p><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1732514654906-1732514654906.png" class="fr-fic fr-dib"></p><p id="isPasted">However, it is important to note that when designing components, the work envelope might be reduced due to tooling size. For example, as shown above, if the cutting bit were longer, the CNC work envelope would be smaller in the Z direction.</p><h3 data-counter-attr="value9"><strong>CNC Axis Travel</strong></h3><p>CNC axis travel is the range over which the cutting tool or workpiece can move along the X, Y, and Z axes. This has a direct impact on the size of components that can be machined. Below is an example of a 3-axis CNC milling machine. In this case, the rail lengths dictate the distances the machining bit can move in each direction.</p><p><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1732514681918-cnc-axis-travel-1536x1536.webp" style="width: 100%px;" class="fr-fic fr-dib"></p><h3 data-counter-attr="value10" id="isPasted"><strong>CNC Axis Types</strong></h3><p>CNC machines typically operate within 3 to 5 axes. Three-axis CNC machines move the cutting tool along the X, Y, and Z axes. Four-axis CNC machines add an additional rotation axis, which increases the complexity of the parts that can be manufactured.&nbsp;</p><p>Finally, five-axis CNC machines add two additional rotation axes to the X, Y, and Z movements. The number of axes significantly affects the size and complexity of components that can be manufactured.</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%2F1732514699442-3-axis4-axis-5-Axis-CNC-Machining.webp" style="width: 100%px;" class="fr-fic fr-dib"><span class="fr-inner">Diagram of 3-axis, 4-axis and 5-axis CNC machines (Source: worthyhardware.com)</span></span></span></p><h2 data-counter-attr="value11" id="isPasted"><strong>CNC Turning Size Limitations</strong></h2><p>CNC turning involves a rotating workpiece, while a single-point cutting tool removes material. The physical geometry of a CNC lathe dictates the size limitations. CNC turning machines are constrained by their centre distance, swing distances, and how the workpiece is mounted.</p><h3 data-counter-attr="value12"><strong>Distance Between Centres</strong></h3><p>For a CNC Lathe, the distance between centres refers to the distance between the lathe headstock and tailstock. This limits the total maximum machinable length of the component that can be machined.</p><p><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1732514792535-Technical-illustrations-01-2048x894.webp" style="width: 100%px;" class="fr-fic fr-dib"></p><h3 data-counter-attr="value13" id="isPasted"><strong>Swing Over Bed, Cross Slide, and Gap</strong></h3><p>The terms “Swing Over Bed,” “Swing Over Cross Slide,” and “Swing Over Gap” define different clearance measurements on a lathe. Swing Over Bed indicates the maximum diameter that can be machined over the bed’s longitudinal guideway.&nbsp;</p><p>“Swing Over Cross Slide” is the diameter allowance over the cross slide, which is smaller than the Swing Over Bed. “Swing Over Gap” indicates a small gap allowing larger diameter parts, such as flanges, to be machined.</p><p><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1732514816151-Technical-illustrations-06-2048x894.webp" style="width: 100%px;" class="fr-fic fr-dib"></p><p id="isPasted">These different swing parameters affect the CNC turning diameter limits and the component length. Here’s a more detailed description:</p><ul><li><strong>Swing Over Bed</strong>: The Swing Over Bed parameter represents the absolute maximum diameter of the workpiece that can be mounted. It is also important to note that the workpiece should be slightly smaller than the swing over the bed.&nbsp;</li><li><strong>Swing Over Cross Slide</strong>: The Swing Over Cross Slide is the maximum diameter of a workpiece that can be machined when the cross slide (the part of the lathe that holds the tool post) is considered. &nbsp;The Swing Over Cross Slide is the limiting factor determining the maximum diameter of a part that can be machined using the full travel of the cross slide. For example, if a 200 mm diameter steel shaft is mounted in the lathe and you want to machine the centre of the shaft to a 100 mm diameter, your Swing Over Cross Slide will need to be large enough to accommodate the 200 mm. If the Swing Over Cross Slide is smaller than 200 mm, the cross slide will likely collide with the shaft. So even if the Swing Over Bed allows for a 200 mm shaft, if the Swing Over Cross Slide does not allow for 200 mm, the shaft, in this example, cannot be machined.</li><li><strong>Swing Over Bed</strong>: The Swing Over Bed parameter represents the absolute maximum diameter of the workpiece that can be mounted. It is also important to note that the workpiece should be slightly smaller than the swing over the bed.&nbsp;</li><li><strong>Swing Over Cross Slide</strong>: The Swing Over Cross Slide is the maximum diameter of a workpiece that can be machined when the cross slide (the part of the lathe that holds the tool post) is considered.&nbsp;The Swing Over Cross Slide is the limiting factor determining the maximum diameter of a part that can be machined using the full travel of the cross slide. For example, if a 200 mm diameter steel shaft is mounted in the lathe and you want to machine the centre of the shaft to a 100 mm diameter, your Swing Over Cross Slide will need to be large enough to accommodate the 200 mm.&nbsp;If the Swing Over Cross Slide is smaller than 200 mm, the cross slide will likely collide with the shaft. So even if the Swing Over Bed allows for a 200 mm shaft, if the Swing Over Cross Slide does not allow for 200 mm, the shaft, in this example, cannot be machined.</li><li><strong>Swing Over Gap</strong>: The Swing Over Gap enables workpieces of larger diameters but significantly limits the length of the component and the angles at which the tool can cut. This can be achieved in some CNC machines by removing a gap block on the lathe bed. However, one should note that this differs from machine to machine and that not all CNC machines have this possibility. The Swing Over Gap enables workpieces of larger diameters but significantly limits the length of the component and the angles at which the tool can cut. This can be achieved in some CNC machines by removing a gap block on the lathe bed. However, one should note that this differs from machine to machine and that not all CNC machines have this possibility.</li></ul><h3 data-counter-attr="value14"><strong>Mounting Method of the Workpiece</strong></h3><p>In typical CNC lathe operations, the workpiece is secured in the headstock and supported by the tailstock. However, for certain tasks, the workpiece is only mounted in the headstock. In these cases, the material type and thickness determine the allowable length of the workpiece, as excessive length can cause flexing and potential issues.</p><p><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1732514839913-Technical-illustrations-04-2048x894.webp" style="width: 100%px;" class="fr-fic fr-dib"></p><h2 data-counter-attr="value15" id="isPasted"><strong>CNC Milling Size Limitations</strong></h2><p>CNC milling machines use rotating cutting tool to remove material from a workpiece. Milling machine size limitations are dictated by the CNC machining work envelope and tool reach.</p><h3 data-counter-attr="value16"><strong>CNC Machining Work Envelope</strong></h3><p>The physical size of the milling machine table (X and Y) and the maximum axis (Z) travel limit the size of the workpiece. One should note that the work envelope does not denote the exact maximum size of the workpiece, and the workpiece might be further limited by the tooling.&nbsp;</p><h3 data-counter-attr="value17"><strong>Tool Reach</strong></h3><p>The length of the cutting tool and the ability to reach different areas without interference places a size limitation on the workpiece. For example, deep features in the part could typically be limited by the tool length rather than the travel of the tool.&nbsp;</p><p>To further illustrate this, if you were to have a part with narrow grooves, as in the image below, the tool length would be the limiting factor as the tool holder would not be able to move past the top face of the component, should the depth of the grooves surpass the length of the tool.&nbsp;</p><p>In terms of accuracy, machines produced by Kern Microtechnik can achieve tolerances as tight as ±2 microns (±0.00007 inches).</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%2F1732514866771-cnc-mill-interior-1536x865.webp" style="width: 100%px;" class="fr-fic fr-dib"><span class="fr-inner">Deep features in the part can typically be limited by the tool length</span></span></span></p><h2 data-counter-attr="value18" id="isPasted"><strong>CNC Drilling Size Limitations</strong></h2><p>CNC drilling is used to create holes in a workpiece, and the size limitations are primarily influenced by the machine’s Z-axis travel and the length of the drill bits. Thus, it is important to ensure that the drill bit length and axis travel surpass the thickness/height of the workpiece that needs to be drilled. Another size limit is the bed size of the CNC drilling machine, which dictates the maximum length and width of the workpiece that can be drilled.</p>

This article reviews the CNC machining size limitations, covering major constraints such as the work envelope of CNC mills and the diameter limitations of CNC-turned parts. It highlights CNC capabilities and size constraints at Xometry, available materials, and post-processing considerations.

CNC Machining Size Limitations: Everything You Need to Know

<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

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