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

<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 id="isPasted">Whether you call it design for manufacturability (DFM), design for manufacturing and assembly (DfMA), or the latest acronym, design for additive manufacturing (DfAM), learning and following its principles is a sure-fire way to improve manufacturing processes and produce higher quality products at a lower cost.</p><p>At first glance, it can seem like a lot to take in. That's because manufacturing is a deep subject, and there's much to know before people consider themselves experts.</p><h2 id="isPasted">Testing the DFM Waters</h2><p id="isPasted">Fortunately, we can simplify the process and ease some of the pain customers might feel when struggling with DFM principles through our intuitive digital quoting platform. &nbsp;<a href="https://www.protolabs.com/en-gb/ecom/get-a-quote/" title="Get A Quote" target="_blank">Begin a project</a> on our website and experience it yourself!</p><p>Once you've selected the desired manufacturing process—CNC machining, 3D printing, or injection moulding—you'll be asked to upload a CAD file. After that, you'll need to answer some questions about the raw material, surface finish, part quantity, and so on.</p><p>Depending on the selected process, you might receive an immediate price and "Ready to Order" notice, but it's more likely that your quote and DFM analysis will arrive within an hour or so. With them, you might also receive one or more <em>design advisories</em>.</p><p>It's essential to read them and follow their recommendations. Design advisories provide helpful advice about the part’s manufacturability. Even though the part design might be okay as is—meaning it’s manufacturable—it could be improved. That's why it's crucial that if you have any questions or concerns, you should contact one of our customer service representatives for help.</p><p><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1725355780031-3dp-dfm-1.jpg" style="width: 600px;" class="fr-fic fr-dib"></p><h2 id="isPasted"><strong>Dealing with DfAM</strong></h2><p>At the risk of stating the obvious, the “A” in DfAM stands for additive. As anyone familiar with the technology will attest, 3D printing offers greater design flexibility than any other manufacturing process. It does, however, present some challenges. Check out some of our other <a href="https://www.protolabs.com/en-gb/resources/design-tips-library/?filter=3dprinting&amp;utm_source=wevolver&amp;utm_medium=referral&amp;utm_campaign=dfm-guidelines-0924&amp;utm_content=wevolver-0924" target="_blank" rel="noopener noreferrer"></a><a href="https://www.protolabs.com/en-gb/resources/design-tips-library/?filter=3dprinting" title="Design Tips Library" data-anchor="?filter=3dprinting" target="_blank" rel="noopener noreferrer">design tips</a>, and you'll discover a wealth of information about common mistakes, size and geometry constraints, and ways to improve part cost, quality, and lead time.</p><p>For example, holes smaller in diameter (about 1.5mm to 2.8mm) can be challenging with any manufacturing process, and 3D printing is no exception. The same can be said for narrow slots and tall walls, especially if they're many times deeper than they are wide. A design advisory might flag these areas as “Review and Accept”, while others throw up a big red “Remove from Quote” flag. Both of these indicate the feature’s level of non-manufacturability.</p><p>But what’s perhaps most unique about additive manufacturing (the “AM” part of DfAM) is its need for support material to keep part layers from curling or sagging during the print process. Exceptions exist, and part orientation plays a significant role in the number and spacing of these scaffold-like structures. Still, the fact remains that support management—though not strictly a DfAM consideration—is one area where a quick chat with one of our applications engineers can lead to better parts and fewer surprises.</p><h2><strong>DFM for Chipmaking</strong></h2><p>Additive manufacturing brings benefits in terms of complexity and ease of manufacturing, but one DFM rule that any designer should live by is this: If the part is easily machined, go with that production method. In fact, thick, blocky parts like hydraulic manifolds and the threaded fittings that go into them might be unprintable due to the amount of heat they acquire during the build. The bottom line is that if you can machine, mould, stamp, or form it, that’s probably the route you should take.</p><p>Speaking of screw threads, here's another tip that might not fall into a purist's DFM bucket but is a common reason for faults: avoid modelling that 1/4-20 tapped hole or 1/2-13 external thread. Yes, Solidworks and Fusion 360 make it easy to do it, but machine shops everywhere—us included—prefer a simple UNC or UNF-style thread callout.</p><p>There’s lots more to know about DFM for <a href="https://www.protolabs.com/en-gb/services/cnc-machining/?filter=cncmachining&amp;utm_source=wevolver&amp;utm_medium=referral&amp;utm_campaign=dfm-guidelines-0924&amp;utm_content=wevolver-0924" target="_blank" rel="noopener noreferrer"></a><a href="https://www.protolabs.com/en-gb/services/cnc-machining/?filter=cncmachining" title="CNC Machining" data-anchor="?filter=cncmachining" target="_blank" rel="noopener noreferrer">CNC machining</a>. Don’t make tolerances any tighter than necessary. Square internal corners on vertical walls add significant cost. Text does, too, especially if it’s raised. Oh, and don’t choose titanium when steel or aluminium will do. Another thing to keep in mind is that very deep pockets and holes may make the part unmanufacturable. Also, just as with injection moulding and 3D printing, thin walls tend to bend or break.</p><p><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1725355847410-protolabs-sheet-metal-process-illustrion-click-to-enlarge-1225-x-793.jpg" style="width: 600px;" class="fr-fic fr-dib"></p><h2 id="isPasted"><strong>Moulding and Beyond</strong></h2><p>Last but certainly not least on the DFM list is <a href="https://www.protolabs.com/en-gb/services/injection-moulding/?filter=injectionmolding&utm_source=wevolver&utm_medium=referral&utm_campaign=dfm-guidelines-0924&utm_content=wevolver-0924" target="_blank" rel="noopener noreferrer">injection moulding</a>. This champion of high-volume plastic part production has its own volume(s) of manufacturing guidelines, some of which contradict those already mentioned. For instance, thin walls won’t deflect during the moulding process like they will during machining and 3D printing, but the molten plastic might not flow into the mould’s harder to reach areas, leading to what’s called a <em>short shot</em>.</p><p>But make those walls too thick and you might experience a phenomenon called sink, which is just as big of an issue. Also, as with over-tolerancing of any manufactured part, overly smooth surface finishes drive up part cost.</p><p>Conversely, rough surfaces tend to reduce processing time with machining and 3D printing, but with injection moulding they can lead to dreaded ejection problems. Then, there are parting lines to contend with where mould halves meet, not to mention undercuts, gate placement, and more. Here's one area where a short chat with a moulding expert can pay big dividends later in the project.</p><p>It may seem daunting initially, but don’t worry! The good news is that, despite the seemingly huge number of DFM guidelines that apply to this and the other manufacturing processes, the design rules built into our quoting process will help to steer you in the right direction. The design advisories that accompany your quote, along with our extensive library of design tips, will also help. And if you need support, you know where to find us. You can speak with one of our application engineers at +44 (0) 1952 683047 or <a href="mailto:customerservice@protolabs.co.uk" target="_blank">customerservice@protolabs.co.uk</a>.</p>

How DFM guidelines save money, reduce lead times, and deliver better products.

The Benefits of Design for Manufacturability Advisories

<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 this detailed guide to CNC turning, we will discuss the turning manufacturing process in depth. We will cover the basics of CNC turning and some common turning processes. After reading this article, you should have a basic understanding of how CNC turning works and what benefits it offers.</p><h2 data-counter-attr="value0"><strong>What is CNC Turning?</strong></h2><p>CNC turning is a subtractive machining process in which a cutting tool removes material from a rotating workpiece. The cutting tool is typically mounted on a computer-controlled turret, and the workpiece is mounted on a chuck or faceplate. As the automated tool moves across the surface of the workpiece, it removes material to create the desired shape.&nbsp;</p><p>CNC turning can create various cylindrical, conical, and helical shapes. It is an extremely versatile machining process that can be used for many applications.</p><h2 data-counter-attr="value1"><strong>CNC Turning Machine Parts</strong></h2><p>Acquiring familiarity with the parts of a CNC turning machine is essential to grasp&nbsp;the process of CNC turning. Turning machine parts vary by manufacturer, kind, and capacity. It’s important to note that all CNC turning machines have several common parts:</p><ul><li><strong>Control unit</strong>: The controller is the brain of the operation, receiving input from the operator and translating it into actions</li><li><strong>Spindle</strong>: It is the part of the machine that holds and rotates the workpiece</li><li><strong>Turret</strong>: The turret is a platform that holds and indexes the cutting tools</li><li><strong>Tool holder</strong>: Tool holders are adjustable devices holding cutting tools on the turret</li><li><strong>Cutting tool</strong>: Cutting tools are used to remove material from the workpiece</li></ul><p><span class="fr-img-caption fr-fic fr-dib" style="width: 790px;"><span class="fr-img-wrap"><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1719495529888-modern-cnc-turning-machine-1024x683.webp" style="width: 100%px;" class="fr-fic fr-dib"><span class="fr-inner">Modern CNC turning machining</span></span></span></p><h2 data-counter-attr="value2" id="isPasted"><strong>How Does a CNC Turning Machine Work?</strong></h2><p>Turning machines were operated manually until computer numerical control (CNC) was introduced. This opened up a lot of potential for errors. Like a painter seeing the final result in his head before beginning work, the machinist had a visual picture of what he wanted to create.</p><p>However, when computer numerical control (CNC) was introduced, turning suddenly became a very precise and accurate multi-step procedure. There are a few steps involved in creating a part using a CNC turning machine:</p><ul><li>First, the product’s <a href="https://xometry.pro/en-eu/articles/cnc-turning-overview/#CAD" target="_blank">CAD</a> model is designed. For this, several computer-aided design (CAD) software can be used. Each component of the final product must be specified in the design.</li><li>The format of CAD files is not recognised by CNC turning machines. Instead, they follow a set of digital instructions called G-Code that tells them where to go and what to do in three-dimensional space. For this reason, it is essential to transform CAD files into G-Code. <a href="https://www.autodesk.com/products/fusion-360/blog/computer-aided-manufacturing-beginners/" target="_blank" rel="noreferrer noopener">Computer-aided manufacturing (CAM)</a> software is useful in this context. Once a CAD model is complete, the designer sends it to a CAM program, which interprets the data and generates the appropriate G-Code for manufacturing.</li><li>The next step is to set up the machine. The operator must prepare the CNC turning machine by mounting the workpiece, clamping the right cutting tool to the turret, and filling the relevant storage with cutting fluid before the CNC program can be performed.</li><li>Once the machine is set up, the operator will start turning using the machine’s control panel. The turning process begins when the machine moves the cutting tool across the surface of the rotating workpiece.</li></ul><h2 data-counter-attr="value3"><strong>CNC Turning Machine Setup</strong></h2><p>The parameters of the CNC turning process are dependent on several factors. These include the material of the part and the tool, the size of the tool, the finishing specifications, etc.</p><h3 data-counter-attr="value4"><strong>Spindle Speed</strong></h3><p>The unit is revolutions per minute, indicating the spindle’s and the workpiece’s rotating speed. The spindle speed is directly proportional to the cutting speed, which also considers the diameter. If the diameter varies dramatically, the spinning tool speed must be adjusted to keep the cutting speed constant.</p><h3 data-counter-attr="value5"><strong>Feed Rate</strong></h3><p>The feed rate indicates the distance the cutting tool travels each turn of the workpiece. The feed rate must be carefully controlled to produce a high-quality finish and to avoid damaging the workpiece or the tool. Too high of a feed rate will cause the tool to skip or chatter, while too low of a feed rate will result in a poor finish.</p><p><span class="fr-img-caption fr-fic fr-dib" style="width: 790px;"><span class="fr-img-wrap"><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1719495558925-feed-rate-300x235.webp" style="width: 100%px;" class="fr-fic fr-dib"><span class="fr-inner">Illustration of Feed Rate (Source: Toolnotes.com)</span></span></span></p><h3 data-counter-attr="value6" id="isPasted"><strong>Workpiece Diameter</strong></h3><p>Workpiece diameter is an important CNC turning parameter that dictates the workpiece size that can be machined. The workpiece diameter is also responsible for the rigidity of the tool as well as the cutting forces.</p><h3 data-counter-attr="value7"><strong>Depth of Cut</strong></h3><p>In CNC turning, the depth of cut (DOC) is one of the most important parameters, as it determines the amount of material that can be removed in a single pass. A too-small DOC will result in a long machining time, while a too-large DOC can cause tool breakage. The ideal depth of cut depends on several factors, such as the machined material, the tooling used, and the spindle speed.</p><p><br><span class="fr-img-caption fr-fic fr-dib" style="width: 790px;"><span class="fr-img-wrap"><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1719495582288-depth-of-cut.webp" style="width: 100%px;" class="fr-fic fr-dib"><span class="fr-inner">Illustration of depth of cut (Source: Toolnotes.com)</span></span></span></p><h2 data-counter-attr="value8" id="isPasted"><strong>Types of CNC Turning Process</strong></h2><p>A CNC turning machine can perform various turning processes, depending on the cutting tool and the machine’s design. Four fundamental CNC turning processes include:</p><h3 data-counter-attr="value9"><strong>Taper Turning</strong></h3><p>Taper turning is a type of CNC turning that involves gradually tapering the diameter of the workpiece. This taper can be produced by changing the angle of the cutting tool or by moving the workpiece along the lathe’s axis. Taper turning is commonly used to create components such as shafts, tapered holes, and spindles.</p><p><span class="fr-img-caption fr-fic fr-dib" style="width: 790px;"><span class="fr-img-wrap"><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1719495615818-taper-turning-operation.webp" style="width: 100%px;" class="fr-fic fr-dib"><span class="fr-inner">Taper turning (Source: Mechanicalbooster.com)</span></span></span></p><h3 data-counter-attr="value10" id="isPasted"><strong>Straight Turning</strong></h3><p>Straight turning is one type of CNC turning, and it is used to create parts with cylindrical surfaces that are parallel to the axis of rotation. This type of turning is well-suited for producing parts with simple geometries, such as axles and pins. The straight-turning process begins with a block of material, known as a workpiece, mounted on a spindle. The spindle rotates the workpiece at high speed while cutting tools shape the material.</p><p><span class="fr-img-caption fr-fic fr-dib" style="width: 790px;"><span class="fr-img-wrap"><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1719495640386-straight-turning-operation.webp" style="width: 100%px;" class="fr-fic fr-dib"><span class="fr-inner">Straight turning (Source: Mechanicalbooster.com)</span></span></span></p><h3 data-counter-attr="value11" id="isPasted"><strong>External Grooving</strong></h3><p>External grooving helps to create a smooth, consistent finish on the outside of a product. This type of turning can be used on various materials, including metals, plastics, and composites. The cutting process begins with a piece of stock mounted on a spindle. A cutting tool is then used to remove material outside the stock, creating a groove. The operator can control the depth and width of the groove, allowing for precise results.</p><h3 data-counter-attr="value12"><strong>Profiling</strong></h3><p>Profiling is the process of cutting a three-dimensional shape into the surface of a workpiece. The tool is mounted on a spindle and rotated at high speeds while the workpiece is fed through the machine at a controlled rate. Profiling can create a wide variety of shapes, including slots and contours.&nbsp;</p><h2 data-counter-attr="value13"><strong>Suitable Materials for CNC Turning</strong></h2><p>Many different types of materials can be used for CNC turning. Some of the most common include metals, plastics, and composites:</p><ul><li>Metals are widely used because they are strong and durable. They can also be machined to tight tolerances, making them ideal for precision parts.&nbsp;</li><li>Plastics are another popular material for CNC turning. They are often less expensive than metals and can be produced in various colours and finishes.</li></ul><p>Here is a non-exhaustive list of common materials used for CNC turning:</p><table><thead><tr><th>Metals</th><th>Plastics</th></tr></thead><tbody><tr><td>Aluminium (2007, 2017A, 6060, 6061, 6082)</td><td>ABS</td></tr><tr><td>Steel (1.0038, 1.0503, 1.0511, 1.0570, 1.2842, 1.7131, 1.7218, 1.7225)</td><td>PEEK</td></tr><tr><td>Stainless steel (303, 304, 304L, 316, 316L, 316Ti)</td><td>Nylon 6 / PA 6</td></tr><tr><td>Copper (2.0060, 2.0065)</td><td>PC (Polycarbonate)</td></tr><tr><td>Brass (2.0401)</td><td>Polypropylene (PP)</td></tr><tr><td>Titanium (Grades 2 and 5)</td><td>POM / Delrin acetal</td></tr></tbody></table><p><span class="fr-img-caption fr-fic fr-dib" style="width: 790px;"><span class="fr-img-wrap"><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1719495671173-CNC-machined-parts-for-the-aerospace-industry-1024x767.webp" style="width: 100%px;" class="fr-fic fr-dib"><span class="fr-inner">CNC machined parts for the aerospace industry</span></span></span></p><h2 data-counter-attr="value14" id="isPasted"><strong>Applications of CNC Turning</strong></h2><p>CNC turning centers are generally well-suited for the production of parts for many sectors. These are three typical industries where this technology is widely used to manufacture parts:</p><h3 data-counter-attr="value15"><strong>Aerospace Industry</strong></h3><p>Many aircraft components are manufactured using CNC turning, and it would be hard to list them all. Nonetheless, some notable examples are the fastener, connector connection, screw, shaft, eccentric hollow shaft, and pin.</p><h3 data-counter-attr="value16"><strong>Automobile Industry</strong></h3><p>A few critical components of a car’s internal combustion engine can be manufactured using CNC machining. A huge aluminium block, for instance, can be machined into a cylinder block. CNC turning is also used to make various automotive parts, including fluid system components, exhaust parts, bushings, suspension components, valve retainers, carburettor housings, and more.</p><h3 data-counter-attr="value17"><strong>Electronic Component Industry</strong></h3><p>The electronics industry is one of the world’s major industrial sectors. It comprises many items, from major consumer electronics to small electrical components. CNC turning can be used to produce a variety of electric components, including heat sinks, sockets and connections, and semiconductors.</p><h2 data-counter-attr="value18"><strong>Advantages of Using CNC Turning</strong></h2><p>CNC turning is a versatile process that can produce parts with a wide range of shapes and sizes, and it offers several advantages over traditional machining methods. Some of the benefits of CNC turning include:</p><ul><li><strong>Increased precision</strong>: CNC turning machines can create parts with extremely high levels of precision. This is because the cutting tools are precisely controlled by computerized systems, which ensures that each cut is identical.</li><li><strong>Greater flexibility</strong>: The machines can be programmed to create parts with various shapes and sizes. This makes them ideal for production runs where the same part must be made in multiple sizes.</li><li><strong>Enhanced productivity</strong>: These machines can run for long periods without needing to be stopped for maintenance or operator intervention. This results in increased productivity and reduced downtime.</li><li><strong>Improved safety</strong>: CNC turning machines are enclosed systems that operate using computer programs. This eliminates the need for operators to be close to the cutting tools, reducing the risk of accidents.</li><li><strong>Reduced costs</strong>: CNC lathes can produce parts quickly and efficiently, which leads to lower production costs. Additionally, computer programs allow for easy design changes, reducing the potential for wasted materials.</li></ul><p><span class="fr-img-caption fr-fic fr-dib" style="width: 790px;"><span class="fr-img-wrap"><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1719495693736-CNC-threaded-cylinders-with-high-precision-1024x683.webp" style="width: 100%px;" class="fr-fic fr-dib"><span class="fr-inner">CNC-threaded cylinders with high-precision</span></span></span></p><h2 data-counter-attr="value19" id="isPasted"><strong>Limitations of CNC Turning</strong></h2><p>CNC turning has several limitations that should be considered before using this CNC machining process.</p><ul><li><strong>Symmetrical parts only</strong>: The primary limitation is that it can only produce symmetrical parts along the axis of rotation. This means that any taper or non-uniformity will have to be accomplished with another machining process.</li><li><strong>Uniform cross-section</strong>: CNC turning can only produce parts with a uniform cross-section. More complex geometries will require using another machining process, such as milling.</li></ul><h2 data-counter-attr="value20"><strong>Conclusion</strong></h2><p>Turning is one of the manufacturing industry’s cornerstones. This manufacturing technique produces the most accurate results for axisymmetric components. CNC turning machines are capable of producing a variety of shapes and sizes with great accuracy. The process is ideal for both small-scale production runs, as well as mass production. Many CNC turning processes are suited to different materials and parts. Large CNC machining centres now have both CNC milling and turning capabilities for increased productivity.</p>

In this article, we'll provide a comprehensive overview of CNC turning technology, its applications across industries such as aerospace and automotive, and its significance in precision engineering.

CNC Turning Technology Overview

The article consists of a comprehensive guide to understanding and applying CNC programming in modern engineering environments. Discover how when done right CNC programming transforms manufacturing processes, enhances precision, and optimizes production workflows.

CNC Programming: Mastering Precision and Efficiency in Engineering

<p id="isPasted">CNC machining where precision meets innovation. In this blog, we'll explore the macroscopic number of technical terms that shape the landscape of CNC machining and dismantle them - to gain a true understanding of their meaning.</p><p>&nbsp;</p><p><strong>Arbor</strong> – a cylindrical shaft or spindle used to securely hold a cutting tool or workpiece in place during machining operations.</p><p><strong>Axis</strong> – The direction along which a cutting tool or workpiece can move under the control of the <a href="https://www.protolabs.com/en-gb/services/cnc-machining/?utm_source=wevolver&utm_medium=referral&utm_campaign=uk-cnc-0524&utm_content=wevolver-a-z-guide-cnc-blog-0524" target="_blank" rel="noopener noreferrer">CNC</a> system. The most common axes are X (left to right or vice versa), Y (front to back or vice versa), and Z (typically up and down).</p><p><strong>Ball Nose End Mill</strong> – a <a href="https://www.protolabs.com/en-gb/services/cnc-machining/cnc-milling/?utm_source=wevolver&utm_medium=referral&utm_campaign=uk-cnc-0524&utm_content=wevolver-a-z-guide-cnc-blog-0524" target="_blank" rel="noopener noreferrer">milling</a> cutter with a rounded tip or “nose” that resembles a ball. Allows the end mill to create contoured surfaces or complex three-dimensional shapes with smooth finishes.</p><p><img border="0" width="570" src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzE2Mzg4Mjg2MjU5LTE3MTYzODgyODYyNTkuanBlZyIsImVkaXRzIjp7InJlc2l6ZSI6eyJ3aWR0aCI6OTUwLCJmaXQiOiJjb3ZlciJ9fX0=" alt="CNC end mill" class="fr-fic fr-dii"></p><p><strong>CAM (Computer-Aided Manufacturing)</strong> – software that converts 3D CAD designs into CNC machine instructions.</p><p><strong>Datum</strong> – a fixed reference point or surface. The datum serves as the origin point from which all measurements and movements of the cutting tool or workpiece are referenced.</p><p><strong>EDM (Electrical Discharge Machining)</strong> – a non-traditional machining process. <a href="https://www.protolabs.com/en-gb/materials/comparison-guide/?category=plastic:metal&process=cncmilling:cncturning&utm_source=wevolver&utm_medium=referral&utm_campaign=uk-cnc-0524&utm_content=wevolver-a-z-guide-cnc-blog-0524" target="_blank" rel="noopener noreferrer">Material</a> is removed from a workpiece through electrical discharges between an electrode and the workpiece submerged in dielectric fluid.</p><p><strong>End Mill</strong> – a type of cutting tool used to remove material from a workpiece.</p><p><strong>Feed Rate</strong> – the speed at which the cutting tool moves along the workpiece during a machining operation. Typically expressed in units of distance per unit of time, such as millimetres per minute (mm/min).</p><p><strong>G-Code</strong> – a programming language used to control the movement and operation of CNC machines. It consists of a series of alphanumeric codes that represent specific commands, movements, tool changes, and other instructions necessary to produce a desired part or component.</p><p><strong>Hard Turning</strong> – a machining process performed on CNC machines that is specifically designed for the high-precision machining of hardened materials. It is an alternative to traditional grinding processes or finishing hardened workpieces.</p><p><strong>High-Speed Machining (HSM)</strong> – is a CNC machining technique that involves using higher cutter speed and feed rates to achieve faster material removal rates while maintaining or improving surface finish and dimensional accuracy. HSM is characterised by its ability to remove material at significantly higher speed than conventional machining processes.</p><p><strong>Indexable Inserts</strong> – also known as indexable cutting inserts or simply inserts, are replaceable cutting tools that can be quickly and easily changed to accommodate different materials and applications. These inserts are typically made of carbide, ceramic, cermet, or other hard materials and are designed to be mounted onto cutting tool bodies, such as end mills, milling cutters, <a href="https://www.protolabs.com/en-gb/services/cnc-machining/cnc-turning/?utm_source=eureka&utm_medium=referral&utm_campaign=uk-cnc-0524&utm_content=eureka-knowledge-a-z-guide-cnc-blog-0524" target="_blank">turning</a> tools, and drills.</p><p><strong>Interpolation</strong> – the process of calculating intermediate points between two known points to create a smooth and continuous path for the cutting tool to follow. Interpolation is essential for generating complex toolpaths that involve curves, arcs, and other non-linear movements. Ther are several types of interpolation – linear, circular, helical and spline.</p><p><img border="0" width="570" src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzE2Mzg4Mjg2MjY3LTE3MTYzODgyODYyNjcuanBlZyIsImVkaXRzIjp7InJlc2l6ZSI6eyJ3aWR0aCI6OTUwLCJmaXQiOiJjb3ZlciJ9fX0=" alt="CNC lathe" class="fr-fic fr-dii"></p><p><strong>Jig</strong> – a device used to hold and locate a workpiece or a tool in the correct position relative to the cutting tool and the machine. Commonly used in CNC to ensure accuracy, repeatability, and efficiency.</p><p><strong>Jog</strong> – “jogging” refers to the manual movement of the CNC machine’s tool or workpiece along a particular axis or direction. It is controlled and incremental movement used for various purposes, such as setting up the machine, positioning the tool or workpiece, checking clearances, or making small adjustments during the machining process.</p><p><strong>Kerf</strong> – the width of material that is removed by a cutting tool during a machining operation, such as milling, routing, or laser cutting.</p><p><strong>Keyway</strong> – refers to a specific type of slot or groove that is cut into a shaft or hub of a mechanical component to accommodate a key.</p><p><strong>Lathe</strong> – also known as a “turning machine” is a machine that rotates the workpiece while a cutting tool is brought into contact with it to remove material and create the desired shape. Lathes offer versatility, precision, and efficiency in producing a wide range of cylindrical or conical components and parts.</p><p><strong>M-Code</strong> – are special commands used to control various auxiliary functions to the machine tool or to activate specific machine operations. They are part of the CNC programming language and are typically used alongside g-codes, which control the movement and positioning of the machine’s cutting tool. Som examples of M code are M03 – for spindle clockwise rotation, M08 for coolant on, or M06 for tool change.</p><p><strong>Machining Centre</strong> – a type of CNC machine that combines several machining processes into one machine. A highly versatile and automated machine tool capable of performing a wide rang of machining operations on a workpiece. Key features include multi-axis capability, automatic tool changer (ATC), spindle, control system, workpiece handling, and integrated coolant systems.</p><p><strong>Nudge</strong> – a small incremental movement of the axes of a CNC machine to fine-tune tool positioning. Typically done using the machine’s control panel, pendant, or jog handle.</p><p><strong>Offset</strong> – the difference between the programmed position of the cutting tool and its actual position relative to the workpiece. Commonly used to compensate for tool dimensions, workpiece dimensions, or machine inaccuracies.</p><p><strong>Overcut</strong> – the intentional extension of a cutting tool’s path beyond the programmed endpoint of a machining operation.</p><p><img border="0" width="570" src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzE2Mzg4Mjg2Mjc3LTE3MTYzODgyODYyNzcuanBlZyIsImVkaXRzIjp7InJlc2l6ZSI6eyJ3aWR0aCI6OTUwLCJmaXQiOiJjb3ZlciJ9fX0=" alt="CNC machining nylon part" class="fr-fic fr-dii"></p><p><strong>Paperless Manufacturing</strong> – the practice of digitising and automating the entire manufacturing process, eliminating the need for paper-based documentation, drawings, and instructions.</p><p><strong>Pocketing</strong> – a machining operation used to remove material from an enclosed area on a workpiece.</p><p><strong>Quick Change Chuck</strong> – a type of workpiece holding device that allows for raid and tool-free mounting and removal of workpieces. &nbsp;Designed to minimise downtime associated with tool changes.</p><p><strong>Quill</strong> – a feature found in certain types of milling machines, particularly manual or semi-automatic. The vertical component on a milling machine that houses the spindle and cutting tool.</p><p><strong>Rapid Traverse</strong> – refers to high-speed movement of the machine’s cutting tool or workpiece. A rapid linear movement along one or more axes of the CNC machine, typically performed at the maximum travel speed.</p><p><strong>Roughing</strong> – the initial phase of material removal from a workpiece during the machining process to achieve the desired shape.</p><p><strong>Spindle</strong> – refers to the rotating component of the machine tool responsible for holding and driving the cutting tool. The spindle rotates at high speed to perform various machining operations such as milling, drilling, boring, or grinding.</p><p><strong>Spindle Speed</strong> – the rotational speed of the spindle. A critical parameter in CNC machining as it directly affects cutting performance, tool life, surface finish, and the overall efficiency of the machining process. Measured in revolutions per minute (RPM).</p><p><strong>Toolpath</strong> – the precise path that a cutting tool follows during a machining operation. There are a variety of toolpaths including, contouring, pocketing, profiling, drilling, 3D machining, and more.</p><p><strong>Undercut</strong> – a recessed or indented feature in a workpiece that prevents the cutting tool from reaching certain areas or angles during machining.</p><p><strong>Vernier Caliper</strong> – a precision measuring instrument used for dimensional inspection of machined parts.</p><p><strong>Virtual Manufacturing</strong> – the use of computer simulations and modelling techniques to analyse, optimise, and validate manufacturing processes before physical implementation. In CNC this can refer to using process simulation, collision detection, toolpath optimisation, fixture and design validation, process validation and verification, and training and skill development.</p><p><strong>Work Coordinate System</strong> – or WCS, refers to a set of reference axes and coordinates used to define the position and orientation of the workpiece or part relative to the CNC machine’s cutting tool.</p><p><strong>Workholding</strong> – the process of securing and clamping the workpiece in place on the CNC machine’s table or fixture during machining operations.</p><p><strong>X-Axis</strong> – horizontal movement (from left to right or vice versa) of the cutting tool along the length of the workpiece. Usually, oriented perpendicular to the Y-axis and parallel to the machine’s bed or table.</p><p><strong>Y-Axis</strong> – horizontal movement (from front to back or vice versa) of the cutting tool along the length of the workpiece. Usually, oriented perpendicular to the X-axis and parallel to the machine’s bed or table.</p><p><strong>Z-Axis</strong> – vertical movement (up and down or vice versa) of the cutting tool. Commonly the z-axis is oriented perpendicular to both the x-axis and y-axis.</p><p><strong>Zero Point</strong> – the reference point from which all coordinates and movements of the cutting tool and workpiece are measured. It serves as the origin for the WCS work coordinate system and is used to define the starting point for CNC programming and machine operations.</p><p>&nbsp;</p><p>These are just some of the terms you may hear referred to when discussing CNC machining. To discover more about CNC machining, <a href="https://www.protolabs.com/en-gb/services/cnc-machining/?utm_source=wevolver&utm_medium=referral&utm_campaign=uk-cnc-0524&utm_content=wevolver-a-z-guide-cnc-blog-0524" target="_blank" rel="noopener noreferrer">visit our webiste</a>.</p><div id="_com_1" language="JavaScript"><p>&nbsp;</p></div>

CNC machining where precision meets innovation.

An A-Z Guide to CNC Machining Technology

<p dir="ltr" id="isPasted">The rapid prototyping industry is incredibly efficient — and hugely competitive. Thanks to the internet, engineers can instantly upload their designs and receive a quote within hours. Depending on the manufacturing process, these parts can often be shipped just a few days later.</p><p dir="ltr">Perhaps the only problem for engineers and product designers is the sheer number of companies offering third-party manufacturing services. Across China and other parts of the world, a huge number of rapid prototyping companies, machine shops, and low-volume manufacturers are competing to provide the best, fastest service.</p><p dir="ltr">Engineers, therefore, need to find out what distinguishes one prototyping company from another. Guangdong’s <a href="https://www.boenrapid.com/" target="_blank" rel="noopener noreferrer">BOEN Rapid's</a> unique selling point is a suite of high-end manufacturing equipment not always offered by other low-cost prototyping companies.</p><h2 dir="ltr">Why quality matters in rapid prototyping</h2><p dir="ltr">In the world of <a href="https://www.wevolver.com/article/rapid-prototypings-transformative-role-to-the-future-of-manufacturing" target="_blank">rapid prototyping</a>, it’s tempting to assume that the two most important factors are speed and cost. After all, the faster a prototype can be delivered, the sooner a product can undergo testing, validation, and production. Faster rapid prototyping means a shorter time-to-market.</p><p dir="ltr">Cost would also seem to be a major factor. Most companies will understandably appreciate a smaller invoice from their prototyping partner, and one would expect engineers to prioritize low costs for prototyping and high quality for production, since nobody will see or use the prototype except company insiders.</p><p dir="ltr">However, there are many reasons why a bad prototype can have negative consequences for product designers. Quality matters at all stages of product design, and prototyping is no exception. Below are just some of the reasons why high-quality prototypes are beneficial.</p><ul><li dir="ltr"><p dir="ltr">Final parts fidelity: Well-made prototypes — those made with skill using professional manufacturing processes — will closely resemble end-use production parts. This means that any testing and validation performed on the prototype will provide more genuine insight about the performance of the final part.</p></li><li dir="ltr"><p dir="ltr">Showcase potential: Product designers don’t just make prototypes for testing. They might also need a visual or functional prototype to show to investors or business partners. In such cases, the visual and mechanical quality of a prototype is virtually as important as the quality of the final parts, as the entire business proposal may depend on it. Quality machining, clean and smooth surfaces, and consistent coloration can all contribute to a successful demonstrator part.</p></li><li dir="ltr"><p dir="ltr">Bridge production: A high-quality prototype isn’t a dead end in the product development cycle. If the prototype is made to a high standard (using the kind of processes and materials that will be used for the final part), its design can be the basis for part production. In some cases, the prototyping company may even provide the first low-volume production run, saving the product designer money.</p></li><li dir="ltr"><p dir="ltr">First-time success: Cutting corners can shorten product development times, but it can also result in prototypes that are simply unusable. Prototypes made without care using low-quality equipment may not meet the designer’s specifications, requiring repeat orders that actually increase the total time and money spent.</p></li></ul><p dir="ltr">In summary, high-quality prototypes provide many benefits. Although end-users won’t see them, quality prototypes can lead to effective testing, persuasive showcasing, and a smoother transition to production.&nbsp;</p><h2 dir="ltr">Why high-end equipment is key to successful prototyping</h2><p dir="ltr">We have seen above why it is important to carry out rapid prototyping to a high standard. But how does one ensure that prototypes ordered from a third party are in fact built to a high standard?&nbsp;</p><p dir="ltr">One key factor is human skill. While many prototyping processes involve digital manufacturing — in which the part is fabricated by a computer-controlled equipment rather than by human hand — these processes still demand a high level of expertise. For instance, project managers require a broad knowledge of different processes, materials, and surface treatments, enabling them to instantly identify the ideal manufacturing solution for a design. These skilled professionals must also be able to read technical drawings (in both 2D and 3D) and understand geometric dimensioning and tolerancing to quickly ascertain the scope, complexity, and feasibility of a design. This degree of knowledge requires many years of training and experience.&nbsp;</p><p dir="ltr"><span class="fr-img-caption fr-fic fr-dib" style="width: 790px;"><span class="fr-img-wrap"><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzE1OTU0NzUzMTk1LUNOQyBtaWRkbGUuanBnIiwiZWRpdHMiOnsicmVzaXplIjp7IndpZHRoIjo5NTAsImZpdCI6ImNvdmVyIn19fQ==" style="width: 100%px;" class="fr-fic fr-dib"><span class="fr-inner">BoenRapid's machine floor. Credit: BoenRapid</span></span></span></p><p dir="ltr">All workers at the facility must possess a similar level of expertise in their designated role. Engineers must validate the proposal in terms of design for manufacturing (DfM), expert machine operators must set up the machines with the correct digital parameters and physical considerations (workholding, clamping, etc.), and finishing specialists must carry out processes like sanding and painting with a high level of manual skill.&nbsp;</p><p dir="ltr">Another element to consider is the raw materials used for the prototype. While many designers use slightly less expensive materials for their prototypes — especially when working with metals — these materials affect the quality of the final prototype. A reliable prototyping company will be able to recommend material choices for a high-quality prototype that remains within the project budget.&nbsp;</p><p dir="ltr">An equally important consideration for making quality prototypes is the quality of the manufacturing equipment. In virtually every area of manufacturing, there is a huge range of machinery available, from budget equipment to the best industrial-grade units used by the world’s most profitable companies. Take fused filament fabrication (FFF) 3D printing, for example. Entry-level machines can cost just a few hundred dollars, while industrial-grade systems with multiple extruders and supreme speed and accuracy often cost six figures.</p><p dir="ltr">At prototyping company BOEN Rapid, the decision was taken to use the best possible equipment to guarantee high-quality prototypes for all customers. This is made apparent in the company’s CNC machining offering, in which it uses 5-axis machines from world-leading hardware companies like DMG MORI (Germany) and HERMLE AG (Germany). 5-axis machining centers provide a much greater degree of geometric flexibility than traditional 3-axis machines and also require fewer setups, greatly reducing cycle times. However, due to the complex toolpath generation required by 5-axis machining, it pays to use only the best hardware and software to eliminate manufacturing errors.</p><p dir="ltr">The quality control stage of rapid prototyping also benefits from high-quality equipment. Here too BOEN Rapid has invested in the best metrology and inspection equipment available, using coordinate measuring machines (CMMs) from ZEISS (Germany) to guarantee that all prototypes meet design specifications within acceptable tolerance limits.</p><p dir="ltr"><span class="fr-img-caption fr-fic fr-dib" style="width: 790px;"><span class="fr-img-wrap"><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzE1OTU0Nzg2MzYwLWNuYyBjZW50ZXIuanBnIiwiZWRpdHMiOnsicmVzaXplIjp7IndpZHRoIjo5NTAsImZpdCI6ImNvdmVyIn19fQ==" style="width: 100%px;" class="fr-fic fr-dib"><span class="fr-inner">Part of BoenRapid's CNC floor. Image credit: BoenRapid</span></span></span></p><h2 dir="ltr">Working with BOEN Rapid</h2><p dir="ltr">BOEN Rapid works with customers of all sizes from a broad range of industries, from automotive and aerospace to medical devices to consumer goods. Regardless of whether you need a single 3D printed prototype or 1,000 aluminum extrusions, BOEN Rapid will make your parts to the highest standards using its high-end equipment. Moreover, the majority of BOEN Rapid engineers have more than a decade of experience and, therefore possess the knowledge and skills required to realize even the most complex prototyping requirements.</p><p dir="ltr">Request a quote from <a href="https://www.boenrapid.com/" target="_blank">BOEN Rapid</a> to discover how this trusted company can become your go-to prototyping and low-volume manufacturing partner.</p>

Rapid prototyping company BOEN Rapid offers a wide range of services, from CNC machining to 3D printing. Behind these processes is an arsenal of high-quality manufacturing hardware.

Why quality equipment matters to cutting-edge prototyping

<p dir="ltr" id="isPasted">Dongguan is located at the heart of China's Pearl River Delta and is renowned as a global manufacturing hub. Over the years, the city has emerged as an important part of the Guangdong-Hong Kong-Macau Greater Bay Area (GBA) by prioritizing advanced manufacturing and technological excellence. By implementing eco-friendly and high-end manufacturing methods, Dongguan is fast becoming a globally influential center for science and technology.</p><p dir="ltr">The manufacturing company, <a href="https://www.boenrapid.com/" target="_blank" rel="noopener noreferrer">BOEN Rapid</a> strategically locates itself in Dongguan leveraging the city's advantages to offer its customers cutting-edge manufacturing services. Established in 2007, the company has earned a reputation for integrity and quality while developing into a leading prototype manufacturing provider in China. It now offers full services in plastic and metal prototyping, rapid tooling, and low-volume manufacturing.</p><p dir="ltr">BOEN Rapid’s positioning in Dongguan is no coincidence. This city's manufacturing sector, among the most diversified and booming, boosted by modern facilities and a large network of material suppliers, offers an ideal environment to thrive. BOEN Rapid is well-located to harness the local treasure trove of resources and technologies in its development to grow into a leading manufacturing center in the city.</p><h2 dir="ltr">The Dongguan Advantage</h2><h3 dir="ltr">Material Availability</h3><p dir="ltr">The manufacturing expertise of Dongguan’s scene largely stems from its extensive network of material suppliers, providing extensive resources that enable companies to innovate and customize, breaking new ground. This environment is crucial for BOEN Rapid's capacity to offer customers a wide array of prototype and manufacturing solutions.</p><p dir="ltr">Leveraging Dongguan's rich selection of materials, BOEN Rapid utilizes materials like ABS for its impact strength in lightweight applications and Polycarbonate (PC) for its clarity in consumer goods, enhancing design and durability. Aluminum and stainless steel offer excellent machinability and thermal conductivity, crucial for aerospace and automotive parts. These materials empower BOEN Rapid to precisely tailor engineering solutions, reflecting the versatility and innovation at the core of their operations.</p><p dir="ltr">This adaptability is paramount in industries where material properties significantly influence the behavior and functions of the final product. With direct access to Dongguan's material supply chain, BOEN Rapid increases its flexibility, enabling it to take on projects that demand a broad range of materials and specifications.</p><h3 dir="ltr">Manufacturing Diversity</h3><p dir="ltr">Dongguan's manufacturing landscape showcases an impressive diversity with technologies ranging from precision CNC machining and additive manufacturing to traditional die casting. This diversity enables engineers to select the most appropriate manufacturing method based on the project's specific requirements, such as material properties, production volume, and complexity of design. Such diversity grants BOEN Rapid a strategic edge, enabling the company to provide full services across the product development lifecycle.</p><p dir="ltr">These advanced manufacturing processes ensure that BOEN Rapid can offer highly precise and efficient rapid prototyping, tooling, and low-volume manufacturing. The company's wide manufacturing capabilities are a testament to its commitment to client-centric solutions. Whether a project requires intricate metal parts with tight tolerances or complex plastic components with unique geometries, the right technology is always available. For their clients, this diversity means faster time-to-market, reduced costs, and superior product quality.</p><h3 dir="ltr">Surface Finishing Excellence</h3><p dir="ltr">Surface finishing is an essential step in manufacturing that enhances the appearance, durability, and performance of products. Dongguan's advanced surface finishing techniques, such as anodizing, powder coating, and electroplating, set it apart as a leader in delivering high-quality manufacturing outputs.</p><p dir="ltr">BOEN Rapid harnesses these sophisticated techniques to elevate the quality of its products, ensuring they meet both aesthetic and functional standards. Whether it's applying a mirror-like polish to metal parts or a robust coating to protect against wear and corrosion, BOEN Rapid's use of Dongguan's surface finishing services ensures that each product looks exceptional and is built to last.</p><p dir="ltr">This emphasis on surface finishing excellence is part of BOEN Rapid's broader commitment to quality and precision, reinforcing its position as a top-tier provider in the competitive landscape of advanced manufacturing.</p><h2 dir="ltr">Integrated Services at BOEN Rapid</h2><h3 dir="ltr">End-to-End Solutions</h3><p dir="ltr">BOEN Rapid delivers an end-to-end experience for customers by utilizing the abundant local resources in Dongguan from the first design conception to the final post-processing. The unique ecosystem of suppliers, the largest and most advanced array of manufacturers' technologies, and the most specialized services in Dongguan enable this comprehensive approach. For BOEN Rapid, this involves controlling every step of the manufacturing process to ensure efficiency, flexibility, and innovation.</p><p dir="ltr">By utilizing local design, engineering, and manufacturing expertise, the company can offer solutions that are tailor-made to perfectly fit their clients' requirements. This holistic approach not only accelerates the speed to market but also ensures the highest quality and performance through services like CNC machining, rapid injection molding, and advanced surface finishing. This process simplifies product development for their clients in the smoothest and most cost-efficient manner.</p><h3 dir="ltr">Rapid Prototyping and Low-Volume Manufacturing</h3><p dir="ltr">The dynamic manufacturing ecosystem of Dongguan is favorable for BOEN Rapid, particularly for quick prototyping and low-volume production. The city's infrastructure, characterized by its flexibility and speed, assists BOEN in being able to iterate designs rapidly. This enables the production of high-quality prototypes or small batches of products with outstanding efficiency. This capability is particularly crucial in today's fast-paced market environment, where taking the lead often distinguishes success from failure.</p><p dir="ltr">Thanks to the wide variety of manufacturing processes and materials available in Dongguan, BOEN Rapid can swiftly turn concepts into tangible prototypes, thereby enabling faster feedback and iterations. This efficiency means that product development cycles are significantly shortened for startups and even established companies, and innovations can reach the market faster and more cost-effectively than ever before.</p><h3 dir="ltr">Quality and Precision</h3><p dir="ltr">Essential to BOEN Rapid's promise to its clients is a balance between precision and quality, achieved through the advanced technology base and highly skilled human resources in Dongguan. The city's commitment to technological innovation and high-quality manufacturing standards ideally positions it for implementing stringent quality control measures.</p><p dir="ltr">With accurate CNC machining and precise 3D printing, BOEN Rapid ensures that every product is manufactured to tight tolerances and performance criteria. The professionals in Dongguan, skilled in various manufacturing disciplines, deeply understand every part of the process and are crucial to achieving these high standards. Their standard of craftsmanship and attention to detail can be the difference between a product that looks good and one that works flawlessly under real-world conditions.</p><p dir="ltr">This dedication to quality and precision enhances BOEN Rapid's reputation as a reliable partner in the highly competitive area of prototype and low-volume manufacturing, setting a benchmark for excellence in the industry.</p><h2 dir="ltr">Conclusion</h2><p dir="ltr">In summary, the strategic positioning of BOEN Rapid in Dongguan provides a compelling case study on how location plays a critical role in the success of a company within the advanced manufacturing industry. Dongguan, with its strong manufacturing ecosystem, serves as a cradle that assures BOEN Rapid can deliver comprehensive, efficient, innovative, and precise services to its customers. The city's vast network of material suppliers, diverse manufacturing capabilities, and advanced surface finishing techniques provide BOEN Rapid with the resources needed to offer versatile and customized solutions to its clients.</p><p dir="ltr">This symbiotic relationship between BOEN Rapid and the Dongguan manufacturing ecosystem exemplifies the mutual benefits of such integration. On the one hand, BOEN Rapid leverages the city’s resources for its service offerings, from rapid prototyping to low-volume manufacturing, ensuring maximum precision for every project. On the other hand, BOEN Rapid helps contribute to Dongguan's position as a global manufacturing hub, providing a robust platform for the city to demonstrate its capability to support high-tech industries and advanced manufacturing processes.</p><p dir="ltr">The strategic advantage gained through this partnership highlights the importance of aligning with local ecosystems that promote innovation and growth. For BOEN Rapid, Dongguan represents not just a location but a competitive edge that allows the company to dynamically respond to the challenges of the global market.</p><p dir="ltr">As both continue to evolve, the relationship between <a href="https://www.boenrapid.com/" target="_blank" rel="noopener noreferrer">BOEN Rapid</a> and Dongguan’s manufacturing ecosystem will undoubtedly continue to yield benefits, propelling the advancement of the manufacturing industry and setting new benchmarks for excellence.</p>

BOEN Rapid offers full services in plastic and metal prototyping, rapid tooling, and low-volume manufacturing by leveraging Dongguan's manufacturing ecosystem in China.

The Manufacturing Ecosystem in Dongguan is driving excellence in manufacturing

Delve into the types and capabilities of CNC machines, empowering engineers with a comprehensive understanding of their diverse applications. This guide equips engineers to leverage CNC technology for innovative solutions across industries.

Types of CNC Machines: Advanced Solutions for Engineers

<p dir="ltr" id="isPasted">At RPWORLD, advancing product innovation for young professionals is deeply rooted in our tradition. We're delighted to support the innovative product designers and engineers as they are on their creative journeys.</p><p dir="ltr">Recently, we sponsored the αCentauri Solar Racing team with customized components needed to the mechanical braking system of their solar car. The αCentauri team, running out of ETH Zurich, is dedicated to cultivating technical talents who are passionate about addressing environmental challenges. This partnership perfectly aligns with our mission to promote innovation and sustainability.</p><h2 dir="ltr">Project Background</h2><p dir="ltr">The initiation of solar car development by αCentauri team was driven by a noble cause&nbsp;—addressing the threat to the nation's lost glaciers due to climate change. The project aimed to use solar energy to redefine sustainable transportation, and to inspire the world towards a more sustainable future. This led them to target the Bridgestone World Solar Challenge. It is a 3,000km race through the Australian outback. In this challenge, 42 teams from 21 countries will race solar cars across Australia, testing both technology and human endurance.</p><h2 dir="ltr">Project Challenges</h2><p dir="ltr">When faced with the challenging task of creating customized parts for the solar racing car, αCentauri team turned to RPWORLD. The team manager expressed his concerns:</p><ul><li dir="ltr">How to choose processes &amp; materials for different mechanical parts: We urgently needed various metal parts for the steering wheel transmission shaft and brackets, but we're not sure about the best manufacturing processes and materials, especially when low quantities are required.</li><li dir="ltr">The project is on a tight deadline: While most components of the solar car were ready, we hope the car could be finalized as soon as possible to complete the test and have the best performance in the challenge. &nbsp;</li></ul><h2 dir="ltr">RPWORLD Solutions</h2><h3 dir="ltr">The Comprehensive DFM Analysis &nbsp;</h3><p dir="ltr">Our dedicated team of engineering professionals love to provide suggestions on manufacturing selection, design optimization, material selection, and post-processing methods for the project. When considering the bracket, the αCentauri team initially intended to use CNC machining. However, with comprehensive analysis, our engineer suggested sheet metal fabrication from Aluminum 5052, with the parts manufactured from a standard sheet metal of 3mm thickness.</p><h3 dir="ltr">Material Selection</h3><p dir="ltr">The steering wheel transmission shaft components demanded aluminum material with exceptional characteristics. Different grades of aluminum materials present distinct characteristics. Here’s the comparison of several commonly used aluminum materials. &nbsp;</p><div dir="ltr" align="left"><table><tbody><tr><td><p dir="ltr">&nbsp;</p></td><td><p dir="ltr">&nbsp;Aluminum</p><p dir="ltr">5083</p></td><td><p dir="ltr">&nbsp;Aluminum</p><p dir="ltr">6061-T651/T6</p></td><td><p dir="ltr">&nbsp;Aluminum</p><p dir="ltr">6063</p></td><td><p dir="ltr">&nbsp;Aluminum 7075-T651/T6</p></td><td><p dir="ltr">Aluminum&nbsp;6082-T6</p></td></tr><tr><td><p dir="ltr">Strength</p></td><td><p dir="ltr">Good</p></td><td><p dir="ltr">Good</p></td><td><p dir="ltr">Good</p></td><td><p dir="ltr">Excellent</p></td><td><p dir="ltr">Excellent</p></td></tr><tr><td><p dir="ltr">Anodizing Effect</p></td><td><p dir="ltr">Good</p></td><td><p dir="ltr">Excellent</p></td><td><p dir="ltr">Excellent</p></td><td><p dir="ltr">Good</p></td><td><p dir="ltr">Excellent</p></td></tr></tbody></table></div><p dir="ltr">We selected aluminum 6082-T6 and aluminum 7075-T651 for the solar racing car project due to their superior strength and good anodizing properties, which are crucial for the high-performance demands of the vehicle.</p><h3 dir="ltr">Manufacturing Solution</h3><p dir="ltr">After a thorough analysis, RPWORLD's engineering experts chose CNC machining and sheet metal fabrication to produce precision components for mechanical braking system. These processes offer precision and customization advantages, ensuring precision and efficiency for these parts.</p><p dir="ltr">To ensure both functionality and visual aesthetics, certain finished parts have also been anodized, not only enhancing their appearance but improving resistance to corrosion. Our comprehensive manufacturing solution enables customer to get components faster, accelerating the solar car development.</p><h2 dir="ltr">Customer Benefits</h2><ul><li dir="ltr">With CNC Machining and other manufacturing solutions, lead time was reduced by 50%.</li><li dir="ltr">Management risks reduced by customized and one-stop solution with multiple processes.</li><li dir="ltr">Production cost was reduced by 40% via changing to more appropriate manufacturing solution.&nbsp;</li><li dir="ltr">High quality parts were assembled seamlessly on mechanical breaking system. &nbsp; &nbsp;&nbsp;</li></ul><blockquote><p dir="ltr">The great part of RPWORLD, was the fast delivery time they gave us, while not compromising on the quality of the product. So, I want to take this moment and thank RPWORLD for the part they delivered, which will enable us to complete at very high level at the Bridgestone World Challenge.</p><p dir="ltr">— &nbsp;Manager of αCentauri Team</p></blockquote>

At RPWORLD, advancing product innovation for young professionals is deeply rooted in our tradition. We're delighted to support the innovative product designers and engineers as they are on their creative journeys.

CNC Machining Accelerates Solar Racing Car Crossing 3,000 Kilometers

In the milling industry, two cutting techniques stand out: climb milling and conventional milling. While both techniques are important in the industry, understanding the differences between the two techniques can impact the quality and efficiency of the product.

Climb vs Conventional Milling: A Comprehensive Comparison

<p dir="ltr" id="isPasted">Are you developing a prototype or mechanical part that features flat surfaces? Although your designs may appear flat, post-production warping can significantly affect prototype validation and part assembly. If your machined part has a flat surface, there’re a few things you should be aware of before freezing the part design.</p><h2 dir="ltr">What is Flatness for CNC Machined Parts?</h2><p dir="ltr">“Flatness” refers to the measurement of surface smoothness and uniformity. It dictates that the flat sections of a component should fit between two parallel planes without protruding. It’s one of the crucial factors for assessing the surface quality of a part, particularly in terms of how it affects the fit and fastening performance of mating components. For instance, in aerospace components, even minor deviations in flatness can lead to significant assembly challenges.&nbsp;</p><h2 dir="ltr">What Factors Influence the Flatness of CNC Machined Parts?</h2><p dir="ltr">Machined surfaces are typically very flat. However, warping can occur due to internal material stress or clamping forces during machining. It’s worth noting that the hardest materials aren’t always the most stable. In some cases, even the toughest materials, such as aluminum and steel, are more vulnerable to bend. Various factors contribute to warpage, including:</p><ul><li dir="ltr">Raw Material: Material type and inherent flatness affects stress and flatness.</li><li dir="ltr">CNC Machine: Precision and condition of the machine impact results. &nbsp;</li><li dir="ltr">Machining Programs and Operator Practices: Program accuracy and operator skill matter.</li><li dir="ltr">Fixturing: Clamping and holding methods can induce stress, leading to warping.</li><li dir="ltr">Material Stress Relief: Proper stress relief techniques prevent warping.</li></ul><h2 dir="ltr">How to Ensure Flatness Within Your Requirements?</h2><p dir="ltr">The degree of warpage in a part is the measured deviation of surface height from the datum plane. The table below helps you select the right flatness tolerances by demonstrating typical ranges for CNC machined parts.</p><p dir="ltr"><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1714056510830-1714056510830.png" width="602" class="fr-fic fr-dii" style="width: 778px; height: 211px;"></p><p dir="ltr">At RPWORLD, we work with a wide range of materials with varying degrees of stability and strive to ensure that flatness tolerances meet your requirements. Take aluminum for instance, which has a relatively large coefficient of thermal expansion. We take several measures to prevent warping when machining thin-wall and thin-sheet components. These measures include:</p><ul><li dir="ltr">Eliminate material internal stresses</li><li dir="ltr">Machine symmetrically</li><li dir="ltr">Machine both sides multiple times</li><li dir="ltr">Choose the appropriate cutting tools</li><li dir="ltr">Improve precision of cutting tool</li><li dir="ltr">Prefer new cutting tools</li><li dir="ltr">Combine the rough machining and finish machining</li><li dir="ltr">Select optimal clamping scheme</li><li dir="ltr">Drill before milling</li></ul><h2 dir="ltr">How to Measure the Flatness of CNC Machined Parts?</h2><p dir="ltr">Probing and optical methods serve as the primary means of measuring flatness. Both methods help detect surface irregularities and ensure parts meet specified tolerance levels, thereby avoiding defects and maintaining high manufacturing standards.</p><p dir="ltr">Common Instruments for Measuring Flatness:</p><p dir="ltr"><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1714056510987-1714056510987.png" width="546" height="233" class="fr-fic fr-dii"></p><h2 dir="ltr">Why Choose RPWORLD for Precision Flatness in CNC Machining?</h2><ul><li dir="ltr">State-of-the-art Equipment for Flatness Measurement: RPWORLD uses advanced CMM (Coordinate Measuring Machine) and feeler gauge solution to inspect flatness, ensuring product accuracy.</li><li dir="ltr">Optimized Tolerance Ranges for Specific Products: Instead of pursuing the absolute minimum tolerance, we create a cost versus tolerance reduction chart to identify the values that align with acceptable range for a part. This helps choose the tight tolerance that fits your project budget.</li><li dir="ltr">Advanced CNC Machines: We utilize state-of-the-art 3-axis, 4-axis, and 5-axis CNC milling and turning machines to achieve the machining consistency and ensure that flatness tolerances meet your requirements. &nbsp;</li><li dir="ltr">Rich Expertise: With 20 years of experience in machining over 100 materials, we know how to eliminate material stress effectively to meet your flatness requirements.</li><li dir="ltr">High-performance Engineering Materials: With a reliable sourcing channel, we stock 100+ high-performance engineering materials, ensuring superior flatness, overall consistency, and quality in our CNC machined parts.</li></ul><hr><p>Partner with RPWORLD for precision CNC machining that meets your exact flatness requirements.<a href="https://www.rpworld.com/en/" target="_blank">&nbsp;Contact Us</a> and kick off your next project today.</p>

Are you developing a prototype or mechanical part that features flat surfaces? Although your designs may appear flat, post-production warping can significantly affect prototype validation and part assembly.

Understanding Flatness in CNC Machined Parts

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