Are you looking to cut costs for your injection molding parts without compromising on quality and functionality? While injection molding process may seem costly compared to CNC machining and 3D printing, there are opportunities to optimize the part and achieve significant cost savings. Here are 6 injection molding design considerations to save you money.<h2 dir="ltr">1. Reduce Material Cost for Injection Molded Parts</h2>Undoubtedly, the prices of plastic materials are continuously rising. Reducing the material of the part without affecting its functionality can reduce part costs, and avoid increased injection time, following by the decreased injection costs. When minimizing material usage for parts, keep the following considerations in mind:<ul style="list-style-type: disc;"><li dir="ltr">Increase part strength by adding reinforcements rather than increasing wall thickness.</li><li dir="ltr">Trim excess material from thicker sections of the part.</li></ul><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1697108430182-6-Ways-to-Reduce-Costs-for-Injection-Molded-Parts_05.jpg" style="width: 300px;" class="fr-fic fr-dib"><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1697108421641-6-Ways-to-Reduce-Costs-for-Injection-Molded-Parts_08.jpg" style="width: 300px;" class="fr-fic fr-dib">Furthermore, consider the alternative materials. Many plastics offer comparable strength and functionality, and are easier to mold, leading to lower part costs. By substituting materials strategically without compromising product quality, manufacturers can unlock additional cost savings.<h2 dir="ltr">&nbsp;2. Avoid the Overly Stringent Tolerance for Part Design</h2>The stricter the plastic part tolerances, the higher the demands on mold accuracy, mold cavity, injection molding process, and inspection. Consequently, the cost of plastic parts increases. Product developers should also be aware of the significant impact of tighter tolerance on the cost of plastic components and mold production. During product design, it is advisable to optimize part design to avoid using excessively stringent tolerance while ensuring the required functionality of the parts.&nbsp;To avoid the part design with overly tight tolerance, considering the following measures:<ul style="list-style-type: square;"><li dir="ltr">Use low shrinkage rate plastics in applications requiring high dimensional accuracy.</li><li dir="ltr">Avoid imposing tight tolerance requirements at mating surfaces such as mold cavities, inserts, slides, etc., as they may introduce additional alignment errors.</li><li dir="ltr">Refrain from the tighter tolerances in the potential warping area on plastic parts. &nbsp;Reinforcements, such as ribs, can be added to mitigate warping.</li></ul><h2 dir="ltr">3. Use Snap-Fit for Fixing Instead of Screws and other Fasteners</h2>The fixation methods for plastic parts include snap-fit, screws, thermal fusion, and ultrasonic welding. Snap-fit allows for quick assembly and disassembly, and it comes with the lowest cost among these options. Using snap-fit can lower the cost of parts while ensuring the requirements for product assembly and functionality. Please refer to our previous article:<a href="https://www.rpworld.com/en/resources/blog/design-tips-for-clips.html" target="_blank">&nbsp;6 Design Tips about Snaps</a><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1697108484557-6-Ways-to-Reduce-Costs-for-Injection-Molded-Parts_12.jpg" style="width: 300px;" class="fr-fic fr-dib"><h2 dir="ltr" id="isPasted">4. Avoid the Unnecessary Features</h2>Undercut is one of the unnecessary features on injection molded parts. Undercut refers to features on a part that prevent proper mold ejection, such as openings and protrusions located on the upper side in the mold’s opening direction. In molds, undercuts are achieved through side-action mechanisms, which are relatively complex structures and contributed to increased mold costs. Common side-action include angled pins and slides. To lower mold costs, avoiding undercuts in part design is crucial. Here are some key approaches:<ul style="list-style-type: disc;"><li dir="ltr">Some external undercuts can be eliminated by redesigning the parting surface. as shown in figure below.</li><li dir="ltr">Redesign part features to avoid undercuts. Many undercut features on parts can be eliminated through optimized design, thereby avoiding the need for side-action and reducing part mold costs. &nbsp;</li></ul><h2 dir="ltr">5. Be Careful with the Decorative Features</h2>For the cosmetic appearance and decorative features of the parts, as well as any text or symbols on them, it is advisable to have them protrude outward, as during mold processing, they should be recessed to facilitate the machining process, further reducing injection molding cost.&nbsp;<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1697108532303-6-Ways-to-Reduce-Costs-for-Injection-Molded-Parts_22.jpg" style="width: 300px;" class="fr-fic fr-dib"><h2 dir="ltr" id="isPasted">6. Choose Overmolding</h2>Finally, consider the possibility of using overmolding. The liquid silicone rubber molding is cost-effective comparing with aluminum or steel mold. Additionally, the complex structure such as undercut can be achieved easily by this process. However, according to the quantities and other specific requirements about your requirements, please consult an engineering expert if the process is feasible for your parts.

Are you looking to cut costs for your injection molding parts without compromising on quality and functionality? While injection molding process may seem costly compared to CNC machining and 3D printing, there are opportunities to optimize the part and achieve significant cost savings. Here are 6 injection molding design considerations to save you money.

6 Ways to Reduce Costs for Injection Molded Parts

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Yes, we won&#39;t be discussing the common sense in CNC design, such as fillets, thin walls, or deep cavities. You&#39;re probably already well-versed in these principles. As experienced mechanical parts engineers, we&rsquo;ve encountered many times design practices that can be enhanced to achieve efficient manufacturing, higher quality, and greater precision. By keeping in mind the following six easily overlooked considerations in CNC part design, you can unlock a world of possibilities and maximize the potential of your designs.<h2 dir="ltr">1. Ensure the Quality of Parts After Heat Treatment</h2>When designing machined parts, it is necessary to consider the quality of subsequent processes such as heat treatment. Sharp edges and corners of parts can lead to stress concentration during quenching, resulting in cracking. Therefore, prior to quenching, the root of the shoulder of a heavy-duty stepped shaft should be designed with fillets, and chamfers should be provided on the shaft end and shoulder, as shown in Figure-1.&nbsp;<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1695815829570-1695815829570.png" width="204" height="171" class="fr-fic fr-dii">Additionally, uneven wall thickness of the part can easily cause deformation during heat treatment. It is advisable to add a process hole appropriately to achieve uniform wall thickness and prevent deformation during heat treatment.&nbsp;<h2 dir="ltr">2. Design for Easy Clamping</h2>Clamping in CNC machining refers to the process of securely securing or holding a workpiece in place during machining operations to ensure stability and accuracy. Designing components for easy clamping means the parts can be accurately positioned and securely clamped, which improves machining efficiency, and ensures the part quality.As shown in Figure-2, in original design, when the part is clamped on the three-jaw chuck, the part and the jaws have point contact, which does not securely hold the workpiece. In the optimized design, a cylindrical section is added to increase the contact area between the workpiece and the jaws, making clamping easier and improving clamping reliability.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1695815829585-1695815829585.png" width="369" height="176" class="fr-fic fr-dii">&nbsp;<h2 dir="ltr">3. Add Flanges or Process Holes to the Large Flat Workpiece</h2>The large flat workpiece was initially challenging to clamp securely during the machining process. By adding flanges to the part, the clamping of the workpiece becomes more convenient and reliable. With the inclusion of flanges, screws and pressure plates can be used to securely hold the workpiece in place. Additionally, the incorporation of flanges facilitates the lifting and handling of the workpiece, making it easier to transport and manipulate.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1695815829600-1695815829600.png" width="373" height="222" class="fr-fic fr-dii"><h2 dir="ltr">4. Reduce the Tool Running Times</h2>By reducing the times of machining tool passes, we can decrease the machining time and consequently reduce the machining costs. As shown in the original design of Figuture-4, when machining features with different heights, it was necessary to individually raise or lower the worktable, which increased the machining time. In the optimized design, several features with different heights are designed to have the same height. This allows machining all the features in a single tool pass, thus improving production efficiency and maintaining relative positional accuracy more easily.&nbsp;<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1695815829487-1695815829487.png" width="352" height="233" class="fr-fic fr-dii"><h2 dir="ltr">5. Reduce Machining Area</h2>Reducing the machining area can decrease machining time and subsequently reduce the cost of mechanical machining. As shown in Figure-5, in the original design, the bottom surface of the bearing component has a large machining area. In the improved design, the machining area was reduced through optimized design, resulting in a decrease in machining volume and tool consumption, improved machining efficiency, and reduced machining costs. Additionally, optimizing the component design by adding convex features or grooves can also help reduce the machining area.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1695815829502-1695815829502.png" width="373" height="255" class="fr-fic fr-dii"><h2 dir="ltr">6. Design for Ensuring Positional Accuracy</h2>Surfaces with mutual positional accuracy requirements are preferably processed in a single clamping operation, which helps ensure the positional accuracy between the machining surfaces and reduces the number of clamping operations. In Figure-6, the inner and outer cylindrical surfaces require coaxiality accuracy. In the original design, the part needs to be clamped twice to machine the outer cylindrical surface and the inner hole separately, making it difficult to meet the coaxiality accuracy requirements. <img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1695815829516-1695815829516.png" width="547" height="251" class="fr-fic fr-dii">In the improved design, by adding a raised platform structure, the inner and outer cylindrical surfaces can be machined in a single clamping operation, making it easier to meet the coaxiality requirements while also reducing the machining cost.

By keeping in mind the following six easily overlooked considerations in CNC part design, you can unlock a world of possibilities and maximize the potential of your designs.

6 Easily Overlooked Considerations in CNC Part Design

The Protolabs Insight video series will help you master digital manufacturing, covering cover specific topics such as choosing the right 3D printing material, optimising your design for CNC machining, surface finishes for moulded parts, and much more.&nbsp;TranscriptHello and welcome to this week&rsquo;s Insight.&nbsp;&nbsp;This time around we&rsquo;re going to be having a chat about complex machined parts, which are becoming more and more common as our CNC machine tools gain greater capabilities.&nbsp;<img width="602" src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNjk0NDE2Njk1OTIxLTE2OTQ0MTY2OTU5MjEuanBlZyIsImVkaXRzIjp7InJlc2l6ZSI6eyJ3aWR0aCI6OTUwLCJmaXQiOiJjb3ZlciJ9fX0=" class="fr-fic fr-dii">&nbsp;Live-tool lathes can now mill various shapes and drill off-axis or radial holes, operations that would once have required a separate trip to the milling department, while machining centres are equipped with indexing heads that scan complete multiple sides of the part in a single operation.&nbsp;However, this doesn&rsquo;t mean that just anything goes. Certain machining rules still apply, and not following them can lead to some incredibly expensive reworks and project delays. Over the next few minutes we&rsquo;re going to have a quick run through five of the top things you need to keep in mind when you&rsquo;re eyeing up a particularly complex part.&nbsp;First up, we have hole placement. You need to keep this in mind because the ideal depth and size of the holes we can put into a part shift a bit depending on where it&rsquo;s located.&nbsp;For example, the minimum size for on-axis and axial holes on the&nbsp;<a href="https://www.protolabs.com/en-gb/services/cnc-machining/cnc-turning/?utm_source=wevolver&utm_medium=referral&utm_campaign=uk-insight-video-0919&utm_content=insight-complex-machined-parts-0923" target="_blank">CNC lathes</a> we use at Protolabs is 1mm, with a maximum depth of six times the diameter. Any narrower or deeper than that, and we start running into problems.&nbsp;Meanwhile, radial holes &ndash; which is to say those drilled from the side of the part &ndash; should be at least two mil in diameter.&nbsp;Now, holes that go all the way through turned or milled parts are usually okay, especially if they&rsquo;re hollow or tube-shaped, but sometimes you might find that the cutting tool doesn&rsquo;t have enough reach. If you&rsquo;re including a part with a hole like that, make sure to chat with your machinists first to clear up any issues.&nbsp;Next, we have particularly deep features. Grooves have a restriction on their maximum depth and minimum width, while all other slot-like milled features generally read from the same playbook as drilled holes in terms of size. Again, a good rule of thumb is to keep the depth less than six times the feature width. Oh, and be sure to leave at least half a mil of wall left on the adjacent material.&nbsp;Unfortunately, deep ribs and grooves can be pretty challenging to work with regardless of their placement. It is possible to cut heat sink-like features on a turned or milled part, but this depends on the actual part geometry and available tools. Again &ndash; and you&rsquo;ve heard this one before &ndash; have a chat with your supplier to clear up any issues.&nbsp;The next thing on our list for today is threading. Designers frequently add threaded features to milled and turned parts, and there are a whole load of options for these, so, yet again, speak to your supplier.&nbsp;For example, at Protolabs we can thread from #4-40 up to about 1/2-20 depending on the type of machine and the feature placement.&nbsp;Having said all that, you might also think about using an insert. Coil and key inserts provide longer service life than bare threads, especially in soft materials like aluminium or plastic, and are super easy for you to install. It won&rsquo;t always be the right answer, but it can be the most convenient and cost-effective one.&nbsp;Right, three down, two to go.&nbsp;And for number four, we have a piece of advice that plenty of us have probably heard already &ndash; texting can often be a bad idea.&nbsp;No, we don&rsquo;t mean on your phones &ndash; not this time, anyway. What we mean is having text milled into your parts.&nbsp;This is a requirement in some sectors, like aerospace and medical work where parts need numbers and names permanently marked, but if you don&rsquo;t really need to include it, our advice would be that you probably shouldn&rsquo;t bother. &nbsp;Recessed text may look nice, but it&rsquo;s also one of the more time-consuming of all machining operations, and is downright prohibitive as production quantities rise.&nbsp;It&rsquo;s usually better to electrochemically etch or laser-mark parts, but if you really must have engraved text, keep it short and sweet with simple, clean fonts. That makes it much easier to mill.&nbsp;Finally, coming in at number five is a quick warning about your corners. If they&rsquo;re too sharp, they can be a real nightmare to machine.&nbsp;For example, the turning tools typically used for finishing here at Protolabs have a 0.8mm nose radius, so any mating parts should be designed with this in mind. Milling cutters go down to 1mm for soft metals and 1.2mm for hard metals and plastics, which means any pockets will contain internal corner radii a little more than half that.&nbsp;Now, that&rsquo;s pretty sharp, but remember that milling with a tool that small takes a real long time and your still left with the pockets. Your best bet is to relieve the internal corners or allow for as large an internal radius as you can on mating part designs.&nbsp;Right, that&rsquo;s our five tips. Hopefully that helped out a little and given you something to think about over the weekend!<hr>&nbsp;Watch other Protolabs Insight videos <a href="https://www.protolabs.com/en-gb/resources/insight/insight-video-library/?utm_source=wevolver&utm_medium=referral&utm_campaign=uk-insight-video-0919&utm_content=wevolver-insight-library-0923" target="_blank">here</a>.

In this video we look at complex machined parts, focusing on the five key things you need to keep in mind when creating a particularly complex part: hole placement, grooves, threading, milled text, and corners.

Protolabs Insight: Mastering Complex Machined Parts

This article covers 10 essential tips for CNC machining design.<iframe width="640" height="360" src="https://www.youtube.com/embed/lb5i00DHGG8?&wmode=opaque&rel=0&enablejsapi=1&origin=https://www.wevolver.com" frameborder="0" allowfullscreen="" class="fr-draggable" data-lf-form-tracking-inspected-kn9eq4roawkarlvp="true" data-lf-yt-playback-inspected-kn9eq4roawkarlvp="true" data-lf-vimeo-playback-inspected-kn9eq4roawkarlvp="true">&nbsp;</iframe><h2 id="isPasted">1. Avoid excessively thin walls</h2>Decreasing the wall thickness affects the stiffness of the material and reduces achievable accuracy as a result of inevitable vibrations during machining. The standard minimum wall thickness is 0.794 mm for metals and 1.5 mm for plastics. If you require thinner walls, you can use other suitable and cost-effective manufacturing processes like <a href="https://xometry.eu/en/sheet-metal/" target="_blank">sheet metal fabrication</a>.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1694002399942-wall-thickness-1440x584.png" style="width: 766px;" class="fr-fic fr-dib">The minimum wall thickness depends on the type of material<h2 id="isPasted">2. Avoid designing features that cannot be CNC machined</h2>An example of a feature in CNC machined parts that CNC mills, lathes or drills cannot produce is &ldquo;curved holes&rdquo;. If you require this feature or others that can&rsquo;t be machined for your design, you can use electrical discharge machining (EDM) instead.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1694002415962-shapes-impossible-cnc-machined.png" style="width: 766px;" class="fr-fic fr-dib"><h2 id="isPasted">3. Avoid excessive use of tight tolerances</h2>If you don&rsquo;t specify tolerances in your design, the machine would simply use its standard tolerance. This helps save time and money. You should only specify tight tolerances when absolutely necessary. If you do specify tight tolerances, you should maintain consistency throughout your design. This helps reduce machining time.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1694002433283-homogeneous-tolerancing.png" style="width: 766px;" class="fr-fic fr-dib">Avoid excessive use of tolerances<h2 id="isPasted">4. Avoid unnecessary aesthetic features</h2>Some aesthetic features cannot be efficiently machined. As a designer, you should ask yourself: &ldquo;What CNC machining process would this feature require?&rdquo; or &ldquo;Is it a 5-axis or a 3-axis machining process?&rdquo;You can improve your design by focusing on the accuracy of required features rather than aesthetics. It is best to use post-machining processes to change aesthetics.<h2>5. Design cavities with accurate depth-to-width ratios</h2>Cavities that are too deep can result in tool hanging, tool deflection, chip evacuation issues, and tool fracture. Cavity depths should not exceed 3-4 times their width. If larger depths are required, you should consider designing your part with a variable cavity depth. Cavity depths higher than six times their width are considered deep.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1694002455698-cavities-cnc.png" style="width: 766px;" class="fr-fic fr-dib"><h2 id="isPasted">6. Add a radius when designing internal vertical edges</h2>Most cutting tools are cylindrical and cannot machine sharp internal edges, meaning it is important to add a radius to internal edges in your design. To avoid unnecessary wear and tear of the tool, a good rule of thumb is to add a radius of 130% of the milling tool radius. If you need sharp internal corners, consider adding undercuts instead of reducing the edge radius.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1694002472729-internal-edges-cnc.png" style="width: 766px;" class="fr-fic fr-dib"><h2 id="isPasted">7. Limit thread length</h2>Unnecessarily long threads increase machining costs. The strength of the connection does not increase any when the thread length exceeds the size of the diameter by more than 1.5 times.<ul><li>Design threads should be no longer than 2 times the hole diameter&nbsp;</li><li>For blind holes, add an unthreaded length of at least half the diameter at the bottom of the hole</li></ul><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1694002491544-thread-length.png" style="width: 766px;" class="fr-fic fr-dib"><h2 id="isPasted">8. Avoid extremely small features</h2>Most CNC machines have a minimum tool diameter of 2.5 mm, meaning any feature smaller than 2.5 mm would be difficult to machine and would require special tools, which increases machining costs and time.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1694002508820-small-features.png" style="width: 766px;" class="fr-fic fr-dib"><h2 id="isPasted">9. Design holes with standard sizes</h2>Holes are machined quickly and accurately when standard drill bits are used. This means you won&rsquo;t need end mills or reamers to finish the hole size to a non-standard dimension.Usually, increments of 0.1 mm are used for holes up to 10 mm in diameter, and increments of 0.5 mm are used for larger holes.You should also limit the depth of holes to four times their diameter. It is possible to machine deeper holes (up to 10 times the diameter), but this will increase costs.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1694002526846-standard-hole-size.png" style="width: 766px;" class="fr-fic fr-dib"><h2 id="isPasted">10. Avoid unnecessary text and lettering</h2>Any required text can be painted or laser engraved on the surface of the machined part during the finishing process. If machined text is required, adhere to the following rules:<ul><li>Choose engraving instead of embossing. This way, less material is removed.</li><li>Use 20-point Sans Serif fonts to help keep costs low. Also, many CNC machines are already programmed for these fonts</li></ul><h2>CNC machining services at Xometry</h2>At Xometry Europe, we offer <a href="https://xometry.eu/en/cnc-milling/" target="_blank">CNC milling</a> and <a href="https://xometry.eu/en/cnc-turning/" target="_blank">CNC turning online services</a>, as well as high-precision, fast, and quality CNC machined parts made of aluminium, stainless steel, steel, copper alloys, and many others. For any questions regarding CNC machining design, you can also refer to our <a href="https://xometry.eu/en/guide/design-guide-cnc-machining/" rel="sponsored nofollow" target="_blank">CNC machining design guide</a>.

The design process for CNC machining requires precision and accuracy to produce quality designs. This is why there are recommended general CNC machining design rules that apply to the most common features of CNC machined parts.

Design Tips For CNC Machining

CNC machining is a powerful manufacturing technology for creating intricate and accurate parts. However, transforming that initial concept into reality can be a complex journey. The design is the first critical step in ensuring the best possible outcome for your project.Creating the 3D model of your part using CAD software needs to factor in the capabilities and limitations of the CNC machining process, as well as material properties and tolerances.To ensure the highest quality of your <a href="https://www.makerverse.com/offering/cnc" target="_blank" rel="noopener noreferrer">CNC machined parts</a>, we made this guide to give you tips and best practices to improve your design. These tips can lead to lower costs, an improved manufacturing process, and better parts.<h2>General Design Rules for CNC Machining</h2>1. Whenever possible, design to lower the cost of labor. Optimizing designs can save time and reduce costs. For example, a chamfered edge –the transitional edge typically at a 45-degree angle &nbsp;– is more manufacturable than a rounded filleted edge.&nbsp;<div data-hook="imageViewer"><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNjkzOTI4MzU3MTU5LTE2OTM5MjgzNTcxNTkucG5nIiwiZWRpdHMiOnsicmVzaXplIjp7IndpZHRoIjo5NTAsImZpdCI6ImNvdmVyIn19fQ==" alt="Different types of edges for CNC machining" class="fr-fic fr-dii"></div>2.&nbsp;Make things as easy as possible&nbsp;for the manufacturing personnel working on your parts. One way to do that is to avoid generalized statements on drawings. Otherwise, it may be difficult for manufacturing personnel to interpret what you mean. Some of the vague comments we've seen include:<ul><li dir="auto">"Polish this surface."</li><li dir="auto">"Corners must be square."</li><li dir="auto">"Tool marks not permitted."</li><li dir="auto">"Assemblies must exhibit good workmanship."</li></ul>Notes must be more specific than this!3. Don't show dimensions from points in space in your designs. Instead, show dimensions from specific surfaces or points on the parts. This helps with fixture and gauge making. Importantly, this avoids potential tooling, gauge, and measurement errors.&nbsp;Furthermore, dimensions should all be from one datum line rather than various points to simplify tooling and gauging and avoid overlap of tolerances.<div data-hook="imageViewer"><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNjkzOTI4MzU3MTA4LTE2OTM5MjgzNTcxMDgucG5nIiwiZWRpdHMiOnsicmVzaXplIjp7IndpZHRoIjo5NTAsImZpdCI6ImNvdmVyIn19fQ==" alt="" class="fr-fic fr-dii"></div> 4. The most important aspect of the design is to fulfill all functional requirements of the part. However, you can focus on making your part lighter once you achieve that.Why focus on lightness? Fewer materials mean lower costs. Furthermore, lighter parts typically leads lower labor and tooling costs. Designers should always strive for the smallest initial raw material that fulfills strength and stiffness requirements. However, look for the raw materials on <a target="_unknown" href="https://www.marks-gmbh.de/shop" rel="noopener noreferrer">online shops</a> to ensure they are available in the size you need.<div data-hook="imageViewer"><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNjkzOTI4MzU2ODU4LTE2OTM5MjgzNTY4NTgucG5nIiwiZWRpdHMiOnsicmVzaXplIjp7IndpZHRoIjo5NTAsImZpdCI6ImNvdmVyIn19fQ==" alt="" class="fr-fic fr-dii"></div>5. Design all the functional geometries on your parts. Add functional geometries to your part, starting from your raw material dimensions and geometry. You should do this because all material extraction results in extra costs. If the part needs to be lighter, use simple geometries like cylinders and blocks and avoid free forms.<div data-hook="imageViewer"><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNjkzOTI4MzU3Mzk5LTE2OTM5MjgzNTczOTkucG5nIiwiZWRpdHMiOnsicmVzaXplIjp7IndpZHRoIjo5NTAsImZpdCI6ImNvdmVyIn19fQ==" alt="" class="fr-fic fr-dii"></div> 6.&nbsp;To further reduce costs, avoid using hardened or difficult-to-machine materials unless their unique functional properties are essential for the part. If you need to search for materials based on mechanical properties like tensile strength, hardness, or chemical composition, <a target="_unknown" href="http://www.steelnumber.com/en/search_form_eu.php" rel="noopener noreferrer">use this tool</a>.7. The <a target="_blank" href="https://www.makerverse.com/supply-chain" rel="noopener noreferrer">MakerVerse supply chain</a> has an extensive collection of standard, general-purpose, and special toolings. Whenever possible, design with general-purpose toolings in mind to reduce costs. Some of those more expensive special toolings include:<ul><li dir="auto">Form cutters</li><li dir="auto">Countersinks other than 90°, 120° and 60°</li></ul>Unless you're dealing with high-volume productions where scale amortizes the labor and material costs of special tooling, it's best to become familiar with all the general-purpose and standard toolings available. There are many tool catalogs (here's <a target="_unknown" href="http://www.hahn-kolb.de/" rel="noopener noreferrer">one example</a> - <a target="_unknown" href="https://www.hoffmann-group.com/GB/en/houk/" rel="noopener noreferrer">and another</a>) where you can see if the needed geometry is possible.8.&nbsp;During the design phase, try to make it so that as many manufacturing operations as possible can be performed without needing to reposition the part. Doing this reduces the required handling and ensures accuracy.9.&nbsp;Use international standards. Define your cutting geometry, norm parts, and processes following international standards (ISO) to ensure they can be understood and produced globally.Furthermore, tolerate dimensions so they can be measured with standard measuring tools. Manufacturing precise tolerances requires constant dimensional checking, so design your part to be measured with micrometers, calipers, gauges, and other standard measurement tools.<div data-hook="imageViewer"><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNjkzOTI4MzU3NDQwLTE2OTM5MjgzNTc0NDAucG5nIiwiZWRpdHMiOnsicmVzaXplIjp7IndpZHRoIjo5NTAsImZpdCI6ImNvdmVyIn19fQ==" alt="" class="fr-fic fr-dii"></div> 10. Use stock dimensions and geometries whenever it eliminates a machining operation or the need for an extra surface.Generally, designers consider the milled part a block where you cut the necessary functional geometries. Turning parts are seen as a cylinder where you remove the required material to create functional features.<div data-hook="imageViewer"><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNjkzOTI4MzU3MzA4LTE2OTM5MjgzNTczMDgucG5nIiwiZWRpdHMiOnsicmVzaXplIjp7IndpZHRoIjo5NTAsImZpdCI6ImNvdmVyIn19fQ==" alt="" class="fr-fic fr-dii"></div>11.&nbsp; Avoid interrupted cuts in single-point machining operations, as they shorten tool levels and prevent using faster carbide or ceramic tools.12. Design your part to be rigid enough to withstand the forces of clamping and machining without suffering distortion. The forces exerted by a cutter can be severe. Same with the clamping forces needed to hold the workpiece securely. Parts with thin walls and webs, deep pockets, and deep holes requiring machining can be challenging.Also, be sure to design the part so that a rigid cutter can be employed while permitting access to the surface. <div data-hook="imageViewer"><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNjkzOTI4MzU4MDc4LTE2OTM5MjgzNTgwNzgucG5nIiwiZWRpdHMiOnsicmVzaXplIjp7IndpZHRoIjo5NTAsImZpdCI6ImNvdmVyIn19fQ==" alt="" class="fr-fic fr-dii"></div>13. Avoid complex contours as much as possible in favor of rectangular shapes for milled parts and cylindrical shapes for turning parts. Make sure that your parts can be fixed on the most standard fixtures.14. Design the part for easy fixturing and secure holding during machining operations. To do this, provide a large, solid mounting surface with parallel clamping surfaces to ensure a secure setup with a minimum of 12 mm high for turning machines.<div data-hook="imageViewer"><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNjkzOTI4MzU3NzY5LTE2OTM5MjgzNTc3NjkucG5nIiwiZWRpdHMiOnsicmVzaXplIjp7IndpZHRoIjo5NTAsImZpdCI6ImNvdmVyIn19fQ==" alt="" class="fr-fic fr-dii">&nbsp; &nbsp; &nbsp; &nbsp; &nbsp; &nbsp; &nbsp;</div>15. Reduce the number and the size of shoulders, as they usually require extra operational steps and material.16. When designing thin, flat pieces that require surface machining, allow sufficient stock for rough and finished machining. In some cases, stress relieving between rough and finished cuts is also advisable. Rough and finish machining on both sides is sometimes necessary. Allow about 0.4 mm stock for finish machining.17. To reduce the amount of required operations, it's best to put machined surfaces in the same plane or, if cylindrical, with the same diameter. When surfaces cannot be in the same plane, design them so they can all be machined from one side or the same setup.18. Provide access room for cutters, bushings, and fixture elements. Design parts so that standard cutters can be used, rather than cutters needing to be ground to a particular form.<div data-hook="imageViewer"><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNjkzOTI4MzU3MjQ4LTE2OTM5MjgzNTcyNDgucG5nIiwiZWRpdHMiOnsicmVzaXplIjp7IndpZHRoIjo5NTAsImZpdCI6ImNvdmVyIn19fQ==" alt="" class="fr-fic fr-dii"></div> 19. Avoid projections, shoulders, etc., which interfere with the overrun of a cutter. Instead, provide clearance space at the end of the cut. The space can be cast or formed to minimize machining. This will also provide a noncritical space for burrs.20. A burr is an unwanted material caused by the CNC machining process. You should expect burrs, provide relief spaces for them, and always design to make it easy to remove them.21.&nbsp;Shorten the length of your tolerances when possible. All CNC machines have a natural axial deviation defined by the producer. Going beyond that deviations requires extra setup.<div data-hook="imageViewer"><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNjkzOTI4MzU3MzUyLTE2OTM5MjgzNTczNTIucG5nIiwiZWRpdHMiOnsicmVzaXplIjp7IndpZHRoIjo5NTAsImZpdCI6ImNvdmVyIn19fQ==" alt="" class="fr-fic fr-dii"></div>22.&nbsp;Avoid thin and long walls, as these tend to deform. If the part is long and thin, you should design with this deformation in mind.&nbsp;23.&nbsp;Many design for manufacturability (DFM) solutions involve splitting the part. Splitting the part generally leads to less complexity,&nbsp;which can unlock the benefits&nbsp;from many tips in this guide.<h2>Designing for On-Demand Manufacturing</h2>The perfect design is a crucial step in the CNC machining process. The other important step is choosing the right place to turn your design into a finished part. MakerVerse gives you a one-stop shop platform for the full range of advanced manufacturing technologies, including CNC machining and additive manufacturing.<a href="https://www.makerverse.com/app/quote/upload/?" target="_blank" rel="noopener noreferrer">Using the MakerVerse platform</a>, you can leverage the full range of technologies without investing in your own machines.Simply upload your design, choose your manufacturing technology and material, and receive your quote with the expected lead time. Our engineering and operations experts can personally assist you with your project.&nbsp;<a href="https://app.makerverse.ai/quote/upload" target="_blank"></a>

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