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.<h2 dir="ltr">What is Flatness for CNC Machined Parts?</h2>“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;<h2 dir="ltr">What Factors Influence the Flatness of CNC Machined Parts?</h2>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:<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>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.<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;">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:<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>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.Common Instruments for Measuring Flatness:<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"><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>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.

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

When selecting the right material for your CNC machined part, hardness is often one of the key considerations. Harder materials resist deformation and scratches, making them longer-lasting and easier to clean and maintain. However, you will often sacrifice toughness if you require a hard material. It may sound contradictory, but if you take glass as an example, it is hard, but its toughness is extremely weak, making it very fragile. On the other side of the scale, plastics are often tough but less resistant to surface and impact damage than metals.So, you’ve decided you want a hard material, but how can you test it to ensure it has the required level of hardness? And if the material you select isn’t hard enough, is there a way to make it harder? Let’s explore those questions in more detail.&nbsp;<h3>How to test material hardness?</h3>When it comes to testing the hardness of your material, there are four generally used methods in <a href="https://www.protolabs.com/en-gb/services/cnc-machining/?utm_source=wevolver&utm_medium=referral&utm_campaign=uk-design-tip-0324&utm_content=wevolver-material-hardness-testing-cnc-dt-0324" target="_blank">CNC machining</a> (and digital manufacturing in general): the Rockwell, Brinell, Vickers and Leeb methods. &nbsp;Rockwell is a common choice due to its non-destructive methodology, suitable for various manufacturing materials. Brinell is better for softer materials or materials with coarse microstructures. If you require precise measurements for materials with high hardness or thin coatings, Vickers may be the most suitable testing method for you. Finally, when needing to perform on-site tests, Leeb offers portability and convenience.<img border="0" width="530" src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzA5NjUwNDY1MjA0LTE3MDk2NTA0NjUyMDQuanBlZyIsImVkaXRzIjp7InJlc2l6ZSI6eyJ3aWR0aCI6OTUwLCJmaXQiOiJjb3ZlciJ9fX0=" alt="Brinell hardness testing method" class="fr-fic fr-dii">&nbsp;At <a href="https://www.protolabs.com/en-gb/?utm_source=wevolver&utm_medium=referral&utm_campaign=uk-design-tip-0324&utm_content=wevolver-material-hardness-testing-cnc-dt-0324" target="_blank">Protolabs</a>, most of our Datasheets use figures achieved through Brinell and Rockwell methods. The table below shows a small selection of our metal materials and the numbers they achieve.&nbsp;<table border="1" cellspacing="0" cellpadding="0"><tbody><tr><td valign="top">Type</td><td valign="top">Material</td><td valign="top">Hardness HB Brinell Hardness (KgF/mm2)</td><td valign="top">HRB Rockwell B</td><td valign="top">HRC Rockwell C</td></tr><tr><td valign="top">Aluminium</td><td valign="top">Aluminium 6082 T651 | 3.2315 | AlSi1MgMn</td><td valign="top">90</td><td valign="top">[~52]</td><td valign="top">&nbsp;</td></tr><tr><td valign="top">Aluminium</td><td valign="top">Aluminium 7075 T651 | 3.4365 | AlZn5.5MgCu</td><td valign="top">150</td><td valign="top">[~80]</td><td valign="top">&nbsp;</td></tr><tr><td valign="top">Stainless Steel</td><td valign="top">Stainless Steel 17-4PH | 1.4542 | X5CrNiCuNb16-4 &nbsp;AS MACHINED</td><td valign="top">&lt;365 (Solution annealed)</td><td valign="top">[~100]</td><td valign="top">[~40]</td></tr><tr><td valign="top">Stainless Steel</td><td valign="top">Stainless Steel 17-4PH | 1.4542 | X5CrNiCuNb16-4 &nbsp;HEAT TREATED</td><td valign="top">400 to 500 (heat treatment H900)</td><td valign="top">[~114 to 117]</td><td valign="top">[~43-47]</td></tr></tbody></table>&nbsp;<h3>What options are there for making my low-hardness material harder?</h3>So, you found a&nbsp;<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-design-tip-0324&utm_content=wevolver-material-hardness-testing-cnc-dt-0324" target="_blank">material</a> that ticks all the boxes, but it’s not hard enough for what you need. What are your options? Well, depending on your material, there may be a few. &nbsp;Options include case hardening, carburising, nitriding, carbonitriding, induction hardening, flame hardening, quenching, precipitation hardening and anodising. &nbsp;So what do all these words mean? And how do they compare?Case Hardening a process used to enhance the surface of a metal object, typically steel, while keeping the interior relatively softer and more ductile.Carburising a heat treatment used to increase the carbon content on the surface layer of low-carbon steel or iron-based alloys.Nitriding a surface-hardening process used to enhance metal surface properties, primarily steel.Carbonitriding a surface hardening process used to improve steel's properties by introducing carbon and nitrogen to the surface layer of the metal.Induction Hardening a surface heat treatment used to increase the hardness and wear resistance of specific areas of metal components.Flame Hardening a heat treatment process used to increase the hardness and wear resistance of specific areas of metal components, particularly steel.Quenching is a critical step in the heat treatment of metals, particularly in processes like hardening, tempering, or annealing. It involves rapidly cooling a heated metal workpiece after it has reached a specific temperature.Precipitation Hardening a heat treatment process used to increase the strength and hardness of certain materials and alloys.Anodising an electrochemical process that creates a protective oxide layer on the surface of metals, particularly aluminium, and its alloys. This process enhances the metal’s corrosion resistance, durability, and appearance.&nbsp;<table border="1" cellspacing="0" cellpadding="0"><tbody><tr><td valign="top">Heat Treatment</td><td valign="top">Purpose</td><td valign="top">Examples of Compatible Materials</td></tr><tr><td valign="top">Case Hardening &amp; Carburising</td><td valign="top">To increase the surface hardness of the metal part, while keeping the core soft.</td><td valign="top">Mild Steels.</td></tr><tr><td valign="top">Nitriding</td><td valign="top">To improve hardness, wear resistance and fatigue strength of metal whilst maintaining a more ductile core.</td><td valign="top">Steel and iron-based alloys.</td></tr><tr><td valign="top">Carbonitriding</td><td valign="top">To increase hardness and wear resistance whilst maintaining a tougher car.</td><td valign="top">Steels and certain iron-based alloys.</td></tr><tr><td valign="top">Induction Hardening &amp; Flame Hardening</td><td valign="top">To increase hardness and wear resistance of specific areas of metal components.</td><td valign="top">Carbon steels and steel alloys.</td></tr><tr><td valign="top">Quenching</td><td valign="top">To increase the hardness of the steel alloy.</td><td valign="top">Mild steels (1045, A36) Alloy steels (4140, 4240) Tool steels (D2, A2, O1)</td></tr><tr><td valign="top">Precipitation Hardening (Aging)</td><td valign="top">To increase the hardness &amp; strength of the metal alloy.</td><td valign="top">Aluminium alloys and Stainless Steel (17-4).</td></tr><tr><td valign="top">Anodising</td><td valign="top">To enhance metal corrosion resistance, durability and appearance.</td><td valign="top">Aluminium and Aluminium alloys.</td></tr></tbody></table><img width="478" src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzA5NjUwNDY1MjEzLTE3MDk2NTA0NjUyMTMuanBlZyIsImVkaXRzIjp7InJlc2l6ZSI6eyJ3aWR0aCI6OTUwLCJmaXQiOiJjb3ZlciJ9fX0=" align="left" alt="Quenching to increase material hardness" class="fr-fil fr-dii">&nbsp;So, there you have it; now you know how to test the hardness of a material and what can be done to make it harder. Whilst this design tip featured primarily on CNC materials and how they can be tested and hardened, the testing methodology is not limited to machining. For example, most of our 3D printed materials have hardness figures available and options for treatments such as annealing, ageing and HIP; learn more <a href="https://www.protolabs.com/en-gb/services/3d-printing/direct-metal-laser-sintering/#post_processing?utm_source=wevolver&utm_medium=referral&utm_campaign=uk-design-tip-0324&utm_content=wevolver-material-hardness-testing-cnc-dt-0324" title="Direct Metal Laser Sintering" target="_blank">here.</a>If you wish to learn more about material hardness testing, you can read our explorative <a href="https://www.protolabs.com/en-gb/resources/guides-and-trend-reports/material-hardness-testing/?utm_source=wevolver&utm_medium=referral&utm_campaign=uk-design-tip-0324&utm_content=wevolver-material-hardness-testing-cnc-dt-0324" title="Material Hardness Testing" target="_blank">guide</a>. For further information on what material hardening options are available through our partner network, view our <a href="https://www.hubs.com/knowledge-base/heat-treatments-cnc-machined-parts/?utm_source=wevolver&utm_medium=referral&utm_campaign=uk-design-tip-0324&utm_content=wevolver-material-hardness-testing-cnc-dt-0324" target="_blank">heat treatments for CNC machined parts</a> page. For advice and support, please reach out to our applications engineer team by calling +44 (0) 1952 683047.<a href="https://explore.protolabs.com/design-tips-registration/?utm_source=wevolver&utm_medium=referral&utm_campaign=uk-design-tip-0324&utm_content=wevolver-design-tip-subscribe-banner-0324" target="_blank" rel="noopener noreferrer"><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzA5NjUwNTAwMzYwLTE3MDk2NTA1MDAzNjAucG5nIiwiZWRpdHMiOnsicmVzaXplIjp7IndpZHRoIjo5NTAsImZpdCI6ImNvdmVyIn19fQ==" class="fr-fic fr-dib"></a>

Ensuring the right level of hardness for your CNC machined part

Material Hardness Testing of CNC Machined Parts

Finding the right supplier for product development and manufacturing can be a challenging and time-consuming task. Some suppliers offer batch production, but this applies to products with a frozen design that cannot be modified. But jumping straight from part design to batch production can be a risky move. Another type of supplier provide single or limited manufacturing services. And product developers have to find more manufacturing suppliers to support along the product development life cycle. At RPWORLD, we offer one-stop shop solution for product development, prototyping, and production, whether it is for low or high volumes.With over 20 years of experience and expertise in manufacturing, RPWORLD has served industries, such as: automotive OEM, Tier I, and Tier II suppliers, biotech &amp; medical device and more. Our four manufacturing solutions provide customers with flexibility and rapidity for all their manufacturing needs.<h2 dir="ltr">CNC Machining with High Precision and Complex Structures (10-1,000pcs)</h2>RPWORLD CNC machining is designed for customers who require precision machined parts with complex structures in medium-to-small volume production runs. With tons of 3-, 4- and 5-axis CNC machines, RPWORLD is capable of producing parts that meets DIN ISO 2768 M (F) standards. Ranging from 10 to 1,000 pieces, RPWORLD CNC machining delivers your accurate and consistent parts in as fast as 3 dasys<h2 dir="ltr">CNC Turning for High-Volume Production (Diameter up to 44mm)</h2>RPWORLD CNC turning, a cost-effective manufacturing process for cylindrical parts that are structurally simple. With expertise in high-volume production of machined parts up to 44mm in diameter, we ensure consistent quality and fast turnaround times using advanced equipment and techniques. This service is perfect for customers who require a high volume of small CNC machined parts for their products.<h2 dir="ltr">High-Volume Injection Molded Parts</h2>With advanced injection molding equipment and our engineering experts dedicated to finding ways to increase production, such as using multi-cavity molds, our injection molding is designed for customers who require large quantities of small injection moled part. And you can also expect the consistent quality from the fast delivery in as fast 7 days.<h2 dir="ltr">Prototyping with Multiple Manufacturing Processes</h2>For prototyping needs, RPWORLD uses a range of manufacturing services, including CNC machining, injection molding, vacuum casting, sheet metal fabrication, finishing options, and more. We are committed to producing complex-geometry prototypes with most fitted process, for industries such as medical devices and automotive components, and can meet your exact specifications.In addition to multiple manfuactuirng processes, RPWORLD also provides Free and Comprehensive DFM analysis for every order. The DFM report includes suggestions for the process, material, surface treatment selection and design optimization from the perspective of manufacturability and assembly. The in-depth analysis helps reduce manufacturing risks before any actual production begins, avoid the costly reworks, and is one of the core benefits for customer to work with RPWORLD.When it comes to finding a reliable partner for your product development and manufacturing needs, RPWORLD offers the turnkey manufacturing solutions. With specialized services in prototyping projects, low- to high-volume CNC machining, and large quantities of injection-molded parts, we can provide a one-stop solution for specific for your manufacturing needs.None of your projects match these requirements? We have engineering experts tailored for your product development.

RPWORLD offers one-stop shop solution for product development, prototyping, and production, whether it is for low or high volumes.

Streamline Your Product Development with RPWORLD Turnkey Manufacturing

<html><head></head><body>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. <iframe src="https://fast.wistia.net/embed/iframe/racvgox81f" width="900" height="450" allowtransparency="true" frameborder="0" scrolling="no" class="wistia_embed fr-draggable" name="wistia_embed" allowfullscreen="" mozallowfullscreen="" webkitallowfullscreen="" data-lf-form-tracking-inspected-kn9eq4roawkarlvp="true" data-lf-yt-playback-inspected-kn9eq4roawkarlvp="true" data-lf-vimeo-playback-inspected-kn9eq4roawkarlvp="true">&nbsp;&nbsp;&nbsp;</iframe> TranscriptHi and welcome to this week’s Insight video.Just to remind you that these videos are here to help you master digital manufacturing. Whether you need parts or prototypes from 3D printing, injection moulding or CNC machining, they are packed full of practical tips to help you get it right.This week we are looking at <a href="https://www.protolabs.com/en-gb/services/cnc-machining/threaded-holes-guidelines/?utm_source=wevolver&amp;utm_medium=referral&amp;utm_campaign=uk-insight-video-0919&amp;utm_content=insight-cnc-threading-0224" target="_blank">CNC threading</a> for <a href="https://www.protolabs.com/en-gb/services/cnc-machining/cnc-milling/?utm_source=wevolver&amp;utm_medium=referral&amp;utm_campaign=uk-insight-video-0919&amp;utm_content=insight-cnc-threading-0224" target="_blank">milled</a> and <a href="https://www.protolabs.com/en-gb/services/cnc-machining/cnc-turning/?utm_source=wevolver&amp;utm_medium=referral&amp;utm_campaign=uk-insight-video-0919&amp;utm_content=insight-cnc-threading-0224" target="_blank">turned</a> parts and what is possible and what is not.&nbsp;Let’s start by looking at what’s typically available.At its simplest level there are two basic types of machined threads, internal and external.Internal threads are machined using either a traditional threading tap or a thread mill. We think you are better off using a thread mill because it offers more flexibility and you can adjust the hole size. This reduces the cost of tooling and time since you don’t need to change it.It also means that you can design custom threads without having to invest in custom taps.Threading for milled parts can be in one of the three cardinal axes, whereas for turning it needs to be perpendicular to the axis of revolution.There are also a few other things that you should check with your supplier.First what size of threads in UNC, UNF and metric do they supply? &nbsp; Check out their website it may be on there.You also need to check the maximum depths for the threads that they can offer. &nbsp;If they are using a thread mill then the depth will increase as the diameter of the threads increase, but more on that later.Internal threads are also available on turned parts. You will find that many of the same rules apply for machining threads using live tooling on a lathe, but the threads available are more limited than with milling.Okay back to the depth of a threaded hole. If you need a hole that is longer than your supplier can do at that diameter, you still have some options.First select the hole from the side that the screw will be started from. If you need the screw to pass all the way through the part, then you can pass a tap through the hole in a secondary process to complete it.You can also select both sides of the feature to be threaded as you can see in image 2. You do however risk the threads being cross threaded as they come from opposite sides. But as long as the threads don’t intersect, then selecting threads from both sides is okay. <img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzA3OTE0NTQxMTk3LTE3MDc5MTQ1NDExOTcucG5nIiwiZWRpdHMiOnsicmVzaXplIjp7IndpZHRoIjo5NTAsImZpdCI6ImNvdmVyIn19fQ==" style="width: 765px;" class="fr-fic fr-dib">&nbsp;Okay let’s take a quick look at external threads.If your parts qualify for turning, then generally there should not be any issues.External milled threads are far less common than internal threads, but they can still be machined. Check that your supplier has this capability. They are produced on the half diameter and then turned around 180 degrees to machine the other side.This works well for larger coarser threads, but you may need to chase the threads to remove any remaining material or mismatch as the threads are produced in two different machining set ups.Smaller external threads are more difficult to produce and you will have to chase the threads with a thread cutting die to remove any material left behind.So, to recap, for standard threaded holes check what diameters your supplier can provide and also what depth these holes can reach.Similarly for external threads it’s worth checking what outer diameter threads are possible and the maximum thread depth that they can achieve for both turned and milled parts.As with all digital manufacturing thinking through the function of the final part and what role the internal or external thread will play could influence your design.There are occasions when you might need an insert to be added into the threaded hole for additional functionality.For example, coil inserts will provide stronger threads. They need to be added after the manufacturing.Similarly key inserts are ideal for thread reinforcement especially if the mating stud or bolt is going to be removed frequently.Check what your supplier provides in terms of inserts and also how they affect both the hole diameter and depth.I’m going to finish off by saying that many CAD packages allow you to display threaded features in different ways. &nbsp;It is a good idea to check with your supplier how these features should be presented and in what file format.Okay that’s it for this week. &nbsp;I know there’s quite a lot of information to take in in this video and also the others that we have done. To find out more take a look at our website where we have produced a number of written practical design tips and guides to help you outUntil next time.<hr> Watch other Protolabs Insight videos <a href="https://www.protolabs.com/en-gb/resources/insight/insight-video-library/?utm_source=wevolver&amp;utm_medium=referral&amp;utm_campaign=uk-insight-video-0919&amp;utm_content=wevolver-insight-library-0224" target="_blank">here</a>.</body></html>

When considering threads for your part there are a number of factors to consider, such as: size of threads in UNC, UNF and metric, maximum depths, whether the thread can be added before or needs to be added after manufacturing, and inserts and how they affect hole diameter and depth.

Protolabs Insight: CNC threading for milled and turned Parts

An In-depth Exploration of CNC Milling's Precision, Repeatability, and Versatility

CNC Milling: A Comprehensive Guide to Understanding and Mastering the Technology

IntroductionEmbarking on the journey of CNC machining can feel like stepping into a realm of complexity, but with advancements like desktop CNC machines, the entry barrier has significantly lowered. In this detailed technical guide, we'll explore the essentials, debunk myths, and introduce you to the world of desktop CNC machining using examples like <a href="https://www.apsx.com/" target="_blank" rel="noopener noreferrer">APSX Machines</a>. Let's equip you with the knowledge to navigate this fascinating landscape.1. The Power of DeterminationThe Challenge:CNC machining demands precision, yet desktop CNC machines like those from APSX Machines make this challenge more accessible. Although they are portable and small, they are precision machines with industry-standard precision.Practical Steps:Imagine designing a prototype for a personal project using a desktop CNC machine. Set achievable goals, such as understanding the basics of tool selection and mastering the software interface. Celebrate each successful run on your desktop CNC, knowing that your determination is opening doors to precision manufacturing.2. Mastering Basic Math SkillsThe Myth:Contrary to the misconception that advanced math is a prerequisite, desktop CNC machines simplify the application of mathematical concepts.The Reality:Picture yourself creating a custom part using APSX's desktop CNC. Basic math skills in geometry and mathematics are essential but are applied in a user-friendly software environment. Explore tutorials provided by APSX Machines, envisioning a hands-on approach to learning CNC programming with ease.Recommended Resources:Consider <a href="https://www.apsx.com/support" target="_blank" rel="noopener noreferrer">APSX's learning materials</a> that emphasize practical examples tailored for desktop CNC machining. Imagine honing your mathematical skills with direct applications to your projects.3. Embracing the Learning CurveUnderstanding the Curve:Desktop CNC machines often have gentler learning curves compared to their industrial counterparts, making the CNC journey less intimidating.Strategies for Success:Envision encountering a challenge on your desktop CNC and overcoming it with the support of APSX's team. Engage in projects that gradually enhance your skills. Picture yourself exploring forums such as <a href="https://www.practicalmachinist.com/forum/" target="_blank" rel="noopener noreferrer">Practical Machinist</a> and <a href="https://www.cnczone.com/forums/" target="_blank" rel="noopener noreferrer">CNCZone</a> where fellow desktop CNC enthusiasts share insights, creating an environment conducive to learning.4. Unveiling OpportunitiesBeyond the Basics:Imagine having mastered the fundamentals on a desktop CNC machine. APSX Machines opens doors to affordable yet powerful solutions.Exploring Specializations:Envision specializing in precision machining with <a href="https://www.apsx.com/apsx-products" target="_blank" rel="noopener noreferrer">APSX's desktop CNC models</a>, offering versatility in applications. Picture yourself contributing to small-scale manufacturing or prototyping with ease, thanks to the accessible technology provided by APSX Machines.ConclusionEmbarking on the CNC machining journey is an exciting endeavor, especially with accessible solutions like APSX Machines. With determination, basic math skills, and a user-friendly learning curve, you'll unlock the vast potential within the desktop CNC machining realm. Are you ready to turn your ideas into precision reality? Your adventure begins now.#CNCMachining #DesktopCNC #PrecisionManufacturing #apsxnano #spydercnc #desktopmachines #desktopmanufacturing #swisscnc #LearningJourney #DeterminationPaysOff

Ever considered diving into the fascinating world of CNC machining, only to be discouraged by naysayers claiming it's too complex or challenging? Well, let's debunk those myths and ignite your passion for mastering CNC machining concepts.

Embarking on the journey of CNC machining

<h2 id="isPasted">Introduction</h2>In the world of precision machining, CNC (Computer Numerical Control) lathes are indispensable tools for manufacturing a wide range of components. Two popular types of CNC lathes are Swiss CNC lathes and regular CNC lathes. In this blog, we'll delve into the key differences between these two lathe types and compare the&nbsp;<a href="https://www.apsx.com/apsx-nano-cnc-swiss-lathe" target="_blank">APSX-NANO</a>, a Swiss CNC lathe, with a&nbsp;<a href="https://www.haascnc.com/machines/lathes.html" target="_blank">HAAS regular CNC lathe</a>.<h2>Swiss CNC Lathe: APSX-NANO</h2>The APSX-NANO is a Swiss CNC lathe known for its precision and ability to create intricate and small parts. This type of lathe is particularly suited for producing small and complex components with tight tolerances. Here are some features and advantages of the APSX-NANO:Guide Bushing: Swiss CNC lathes like the APSX-NANO utilize a guide bushing, which provides excellent support to the workpiece, minimizing vibration and ensuring precise machining. This feature is crucial when working with small, delicate parts.Material Feeding: In Swiss CNC lathes, the material is fed through a guide bushing, allowing for the creation of long and slender parts with exceptional precision. The ability to work with bar stock efficiently is a distinct advantage.Tooling Setup: The APSX-NANO allows for quick tool changes, reducing downtime between setups and enhancing overall productivity. It also offers two live tools for extra versatility.<h2>Regular CNC Lathe: HAAS</h2>HAAS is a well-known manufacturer of regular CNC lathes. These machines are versatile and widely used in a variety of industries for both small and large-scale production. Let's examine the key features and advantages of a HAAS CNC lathe:Chucking: Regular CNC lathes use chucks to hold the workpiece, which is different from the guide bushing used in Swiss CNC lathes. This chucking system is suitable for a wide range of part sizes and shapes.Material Handling: HAAS lathes can handle a broader spectrum of materials, making them a preferred choice for general machining applications. They are not limited to bar stock and can work with castings, forgings, and more.Tool Capacity: Regular CNC lathes often have a higher tool capacity, allowing for more tooling options during the machining process. This is advantageous for complex part production.Simplicity: HAAS lathes are generally considered more straightforward to operate and set up compared to Swiss CNC lathes. They are a better choice for shops that need versatility and ease of use.<h2>Choosing the Right Lathe</h2>The choice between a Swiss CNC lathe like the APSX-NANO and a regular CNC lathe like HAAS depends on your specific machining needs. Consider the following factors when making your decision:Part Complexity: If you primarily work with intricate, small parts, a Swiss CNC lathe may be the better choice.Material Variety: If your machining tasks involve a wide range of materials, a regular CNC lathe may be more versatile.Tooling Requirements: Assess your tooling needs and the number of tools required for your projects. This will help determine whether a regular or Swiss CNC lathe is more suitable.Production Volume: Consider the volume of parts you need to produce. For high-volume production, a regular CNC lathe may be more efficient, while Swiss CNC lathes excel at small-batch and precision work.<h2>Conclusion</h2>Both Swiss CNC lathes like the APSX-NANO and regular CNC lathes like HAAS have their own set of advantages and applications. The choice between them ultimately comes down to your specific machining needs and production requirements. By understanding the key differences and features of each type, you can make an informed decision and select the lathe that best suits your manufacturing operations.

In the world of precision machining, CNC (Computer Numerical Control) lathes are indispensable tools for manufacturing a wide range of components. Two popular types of CNC lathes are Swiss CNC lathes and regular CNC lathes. 

Swiss CNC Lathe vs. Regular CNC Lathe: A Comparative Analysis

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

<h2 id="isPasted">Introduction</h2>Modern hardware engineering teams are facing a productivity crisis. Research commissioned by Dassault Syst&egrave;mes shows that, on average, engineers spend just 51%[1]<a href="https://www.getanneal.com/engineering-productivity.html#ref" target="_blank"></a> of their time on innovation and design work. It also shows that they are typically working with outdated information 20% <a href="https://www.getanneal.com/engineering-productivity.html#ref" target="_blank"></a>[1] of the time, meaning that engineers are able to dedicate just 41% of their time to innovative, productive work with up-to-date input data.<img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNjk0MDg5NjQ5NzI2LUVuZ2luZWVyVGltZVV0aWxpc2F0aW9uLnBuZyIsImVkaXRzIjp7InJlc2l6ZSI6eyJ3aWR0aCI6OTUwLCJmaXQiOiJjb3ZlciJ9fX0=" style="width: 302px;" class="fr-fic fr-dib">Derived from [1]. Drawing office challenges of this nature are adversely affecting both product quality and time-to-market for product businesses, with Autodesk research indicating that 35%[2]<a href="https://www.getanneal.com/engineering-productivity.html#ref" target="_blank"></a> of engineers report missing due dates during the design process. These challenges are also recognised by engineering leaders, with more than 94% [3] of engineering executives shown to recognise the need for improved mechanical engineering productivity.<img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNjk0MDg5NjgwOTgxLURlc2lyZWRJbXByb3ZlbWVudC5wbmciLCJlZGl0cyI6eyJyZXNpemUiOnsid2lkdGgiOjk1MCwiZml0IjoiY292ZXIifX19" style="width: 300px;" class="fr-fic fr-dib">Reproduced from [3]. <hr><h2 id="isPasted">The Cause</h2><h3>A Fragmented Approach to Information Management</h3>Dassault&#39;s research[1]<a href="https://www.getanneal.com/engineering-productivity.html#ref" target="_blank"></a> permits further breakdown of engineer time demands. It shows that 25% of all &#39;non-value-added&#39; engineer time is consumed by simply searching for information, with significant time also spent collecting data for other stakeholders, and repeating work when information could not be found.Considering why this may be the case, an engineering practices and procedures survey[4]<a href="https://www.getanneal.com/engineering-productivity.html#ref" target="_blank"></a> provides some indication, with results demonstrating that e-mail, meetings, and telephone remain the dominant mechanisms for communication and collaboration in contemporary engineering teams. These channels are private by design, with participants having to take active, post-hoc steps to share outcomes with team members. Important technical information shared via these routes is also frequently rendered undiscoverable; hidden from other team members, exempted from version control, and put beyond the ready reach of any new hire.<img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNjk0MDg5NzE0NDY1LUNvbGxhYm9yYXRpb25Ub29sLnBuZyIsImVkaXRzIjp7InJlc2l6ZSI6eyJ3aWR0aCI6OTUwLCJmaXQiOiJjb3ZlciJ9fX0=" style="width: 300px;" class="fr-fic fr-dib">Drawn from the results of [4]. &#39;Issue Tracking System&#39; refers to software development-focused products: JIRA, GitHub, GitLab etc. <h3 id="isPasted">Design Review Procedures: A Persistent Threat</h3>Checking and approval procedures are a key component of engineering best practice. Many organisations run a stage-gate process, typically with at least two review stages, but often with more. In general, there are two broad categories of review and approval procedures involved in physical system design and development:<ol><li>A high-level concept review, typically completed earlier in the design process. This review assesses the design concept against broad objectives, and does not address minor design or manufacturing details.</li><li>A detailed checking and approval procedure for finalised drawings, completed prior to system components being formally released via an ECN or ECO procedure.</li></ol>The results of <a href="https://www.getanneal.com/engineering-productivity.html#ref" target="_blank">[4]</a> tell a story of inadequate tooling, with in-person meetings and e-mailed screenshots dominating the approaches taken by modern engineering teams. In both cases, these methods offer very poor visibility&mdash;typically failing to capture topics discussed, decisions taken, and action items agreed.However, the latter approach is considered particularly pernicious: it places vast time demands on the engineer requesting review. They are obligated to manually select and annotate salient views of their design, then distribute these to a wider set of stakeholders. This set of stakeholders then returns the documents with their own annotations, and the engineer initiating the review must collate and address multiple possibly conflicting comments from disparate sources.&dagger; <img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNjk0MDg5NzQ1OTQ2LVJldmlld01ldGhvZG9sb2d5LnBuZyIsImVkaXRzIjp7InJlc2l6ZSI6eyJ3aWR0aCI6OTUwLCJmaXQiOiJjb3ZlciJ9fX0=" style="width: 300px;" class="fr-fic fr-dib">Drawn from the results of [4].&dagger;Though Anneal currently has no robust data to support a quantitative assessment of the impact of the screenshot and e-mail based design review process, it is a topic frequently encountered during customer conversations, with the typical procedure involving the assembly of a multiple page PowerPoint presentation of salient views which is then e-mailed to a number of reviewers for comment.<hr><h2 id="isPasted">The Cost</h2>The damaging consequences of poor visibility and discoverability of technical information are clear to see: engineers must spend more time looking for information, they must repeat previously completed tasks, and they must complete remedial rework in the wake of design progressing with out-of-date values. Dassault&#39;s research[1] provides values for the most frequently reported consequences of bottlenecks in collaboration and shortcomings in information discoverability that result in outdated information feeding into the design process.<img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNjk0MDg5ODAyMzQ4LUNvc3QucG5nIiwiZWRpdHMiOnsicmVzaXplIjp7IndpZHRoIjo5NTAsImZpdCI6ImNvdmVyIn19fQ==" style="width: 300px;" class="fr-fic fr-dib">Recreated from [1]. Further considering the impact of outdated information in design, survey results indicate that more than half of engineering organisations[4]<a href="https://www.getanneal.com/engineering-productivity.html#ref" target="_blank"></a> have encountered problems arising from out-of-date values persisting through design iterations, with these ranging from time-pressured and costly late-stage rework of a given design, through to catastrophic failure of a large-scale product prototype.All considered, the prevailing approach to managing the design and development of complex hardware systems appears to be failing for many teams. Engineers are bogged down in non-technical workload, and their tools are not providing adequate support. With engineers spending just 41% of their time&mdash;two days per week&mdash;on productive, innovative work, individual companies are spending hundreds of thousands of dollars on misdirected engineering resource, and could be losing millions in the marketplace through degraded product quality, stretched development cycles, and delayed product introductions.<hr><h2 id="isPasted">The Solution</h2>For most teams, the best mitigation for this productivity crisis will require two things: modified behaviour, and modified tools.On behaviour, engineering teams must adopt more open, collaboration-centric mechanisms for communication. They should consider reducing task scope, mixing disciplines, and assigning ownership to all work. More importantly, they should prioritise seeding a writing culture, take steps to make engineering decision making readily interrogable, and champion visibility and transparency amongst their team.On tools, software should be sought or developed to support the behavioural change. Engineering teams should seek access to software that enables both real-time and asynchronous peer review of drawings, CAD files, and technical reports. They should seek software that allows engineering topics to be discussed in context, that allows them to view task progression and workload distribution across a project, and that allows them to leverage modern web application technology to accelerate product development and improve product quality&mdash;wherever the team is.<hr><ul><li>[1]: Reduce Non Value Added Work, Dassault Syst&egrave;mes &amp; Tech Clarity&nbsp;</li><li>[2]: Extending PDM Beyond Design Data Management, Autodesk &amp; Tech Clarity&nbsp;</li><li>[3]: The CAD Productivity Research Report, Siemens &amp; Lifecycle Insights&nbsp;</li><li>[4]: Engineering Practices &amp; Procedures Survey, Anneal</li></ul>

The average engineer spends just 41% of their time on productive, innovative work⏱️

The Engineering Productivity Crisis

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.ai/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 &ndash;the transitional edge typically at a 45-degree angle &nbsp;&ndash; is more manufacturable than a rounded filleted edge.&nbsp;<div data-hook="imageViewer"><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1693928357159-1693928357159.png" 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&#39;ve seen include:<ul><li dir="auto">&quot;Polish this surface.&quot;</li><li dir="auto">&quot;Corners must be square.&quot;</li><li dir="auto">&quot;Tool marks not permitted.&quot;</li><li dir="auto">&quot;Assemblies must exhibit good workmanship.&quot;</li></ul>Notes must be more specific than this!3. Don&#39;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://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1693928357108-1693928357108.png" 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://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1693928356858-1693928356858.png" 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://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1693928357399-1693928357399.png" 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.ai/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&deg;, 120&deg; and 60&deg;</li></ul>Unless you&#39;re dealing with high-volume productions where scale amortizes the labor and material costs of special tooling, it&#39;s best to become familiar with all the general-purpose and standard toolings available. There are many tool catalogs (here&#39;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://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1693928357440-1693928357440.png" 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://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1693928357308-1693928357308.png" 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://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1693928358078-1693928358078.png" 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://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1693928357769-1693928357769.png" 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&#39;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://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1693928357248-1693928357248.png" 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://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1693928357352-1693928357352.png" 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://app.makerverse.ai/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>

These 23 tips will help ensure the manufacturability of your CNC machined parts.

The Guide to Designing Parts for CNC Machining

<div data-mesh-id="comp-llgao0tzinlineContent" data-testid="inline-content"><div data-mesh-id="comp-llgao0tzinlineContent-gridContainer" data-testid="mesh-container-content"><div data-testid="richTextElement">Pushing the boundaries of space technology requires innovative thinking and the right tools for the job.The Scientific Workgroup for Rocketry and Spaceflight (<a href="https://warr.de/en/" target="_blank" rel="noreferrer noopener">WARR)</a> at the Technical University of Munich launched their cryogenic rocket 12.7 kilometers above the earth. See how the group transformed &ldquo;Project Cryosphere&rdquo; from an idea to a reality with critical parts made by <a href="http://www.makerverse.ai" target="_blank" rel="noopener noreferrer">MakerVerse</a>. <img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNjkyNzcyMDEwOTc5LVJvY2tldCBpbiBmbGlnaHQuSlBHIiwiZWRpdHMiOnsicmVzaXplIjp7IndpZHRoIjo5NTAsImZpdCI6ImNvdmVyIn19fQ==" style="width: 300px;" class="fr-fic fr-dib">Project Cyrosphere successfully takes off. Photo credit: Matthew Swenson.<div data-testid="richTextElement" id="isPasted"><h3>The challenge: Blasting Off to 11 Kilometers</h3></div><div data-testid="richTextElement">Since its foundation in 1962, WARR has been no stranger to ambitious space-related projects. Within that group is WARR Rocketry, whose student members come from all backgrounds ranging from mechanical engineering to business.The team&rsquo;s previous altitude record was 4 kilometers. With Project Cyrosphere, they wanted to go far beyond. WARR knew they needed an impeccable design and perfect parts to achieve that goal. One of the significant challenges is the extreme conditions that the rocket would undertake. The 135-kilogram rocket would travel 3.5 times the speed of sound, undergoing intense strain until reaching the apogee. Every part must be precisely manufactured to handle severe heat and cold.Furthermore, the student group faced tight deadlines to complete the rocket in time for the scheduled launch in California (US).<div data-testid="richTextElement" id="isPasted"><h3>The solutions: MakerVerse for the Universe</h3><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNjkyNzcyNDQyMjQzLVdBUlIgcGFydHMgKEFwcHJvdmVkKSAoNCkucG5nIiwiZWRpdHMiOnsicmVzaXplIjp7IndpZHRoIjo5NTAsImZpdCI6ImNvdmVyIn19fQ==" style="width: 766px;" class="fr-fic fr-dib">The interior and exterior of the aluminum critical connectors made by MakerVerse. They&#39;re attached to carbon fiber.</div><div data-testid="richTextElement">WARR&rsquo;s rocket is made largely of carbon fiber, as this material combines strength with reduced weight. For the crucial connector interfaces, which connect the carbon fiber with the cryogenic tank and the upper segments of the rocket, WARR turned to MakerVerse.With MakerVerse&rsquo;s<a href="https://app.makerverse.ai/quote/upload" target="_self" rel="noreferrer noopener">&nbsp;on-demand manufacturing platform</a>, WARR gained access to the full range of manufacturing technologies and materials. In this case, <a href="https://www.makerverse.ai/cnc" target="_self" rel="noreferrer noopener">CNC machining&nbsp;</a>created these aluminum connectors to exact specifications. Considering the delicacy and difficult conditions, MakerVerse&rsquo;s attention to detail was critical.<img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNjkyNzcyMjIwOTA1LVdBUlIgcGFydHMgKEFwcHJvdmVkKSAoMikucG5nIiwiZWRpdHMiOnsicmVzaXplIjp7IndpZHRoIjo5NTAsImZpdCI6ImNvdmVyIn19fQ==" style="width: 427px;" class="fr-fic fr-dib">The assembled structure.Throughout the process, MakerVerse provided very clear pricing and communications, which helped ensure all lead time expectations were met.<div data-testid="richTextElement" id="isPasted"><h3>The results: Reaching for the Stars</h3></div><div data-testid="richTextElement">With the successful launch of its cryogenic rocket WARR, gained invaluable date on supersonic flight and the performance of the hardware. This data will be put to use for other projects. The team already has other ambitious projects planned for the near future, including innovative new rocket designs. For these projects, WARR plans to work with MakerVerse again using a combination of additive manufacturing, CNC machining, and other technologies as needed.&ldquo;MakerVerse was a great partner for our manufacturing projects,&rdquo; said Francesco Longhetti, Head of WARR Rocketry. &ldquo;They helped save us a lot of time.&rdquo;</div></div></div></div></div></div>

See how the student group from Technical University of Munich reached an altitude of nearly 13 kilometers with their rocket launched in the US.  Some key components were made by MakerVerse, the on-demand manufacturing platform for industrial-quality parts. 

WARR Launches Cryogenic Rocket with Machined Parts

Demystifying Overmolding: A New Approach with the APSX-PIM&nbsp;In the dynamic manufacturing realm, innovations often redefine conventional processes, leading to improved outcomes and enhanced efficiency. One such transformation can be observed in overmolding applications, where the <a href="https://www.apsx.com/desktop-injection-molding-machine" target="_blank" rel="noopener noreferrer">APSX-PIM injection molding machine</a> challenges the traditional myth associated with vertical injection molding machines. Let&#39;s explore how the APSX-PIM is changing overmolding by offering a new approach and efficient solution.&nbsp;Rethinking Overmolding with the APSX-PIM&nbsp;Historically, vertical injection molding machines have been the go-to choice for overmolding applications. The reasoning behind this preference lies in the idea that gravity assists in ensuring seamless adhesion of the overmolded material to the existing substrate.&nbsp;Introducing the APSX-PIM: A New Overmolding Paradigm&nbsp;The APSX-PIM, an innovative horizontal injection molding machine, has emerged as a transformative solution for overmolding applications. Unlike traditional vertical machines, the APSX-PIM introduces a fresh perspective, addressing the shortcomings and inefficiencies of the conventional approach.The APSX-PIM suggests using magnets behind the mold to hold the overmolded metals. The user can place the metal parts in specifically designed slots because the magnets behind them are strong enough to hold them precisely. For plastic parts, a snapping mechanism can be used instead of magnets.&nbsp;Advantages of the APSX-PIM for Overmolding&nbsp;Versatile Design: The horizontal configuration of the APSX-PIM allows for more flexible mold designs and adaptability, accommodating diverse overmolding projects.Space Efficiency: The compact footprint of the APSX-PIM optimizes floor space in manufacturing facilities, contributing to a more efficient workspace layout.Simplified Maintenance: The modular design of the APSX-PIM streamlines maintenance procedures, minimizing downtime and ensuring consistent production.Cost-Effective Operation: APSX-PIM&#39;s cost-effectiveness in terms of initial investment and ongoing operational expenses positions it as an attractive option for various business scales.&nbsp;Illustrating the APSX-PIM Approach to OvermoldingConsider a scenario where an ergonomic plastic grip needs to be overmolded onto a metal part. The APSX-PIM&#39;s approach to this process is outlined below:Material Selection: Choose compatible materials for the metal part and the overmolded grip, considering material compatibility, adhesion, and desired properties.Mold Design: Develop a mold design that accommodates the metal part and integrates necessary injection channels. The horizontal orientation of the APSX-PIM facilitates straightforward mold designs.Injection Process: Load the selected materials into the APSX-PIM&#39;s hopper. Configure injection parameters like temperature, pressure, and cycle time based on material specifications.Injection and Cooling: The APSX-PIM injects the molten plastic material over the metal part. The horizontal setup promotes uniform material distribution and efficient cooling.Completed cycle: After the overmolded part solidifies, the mold opens, and the finished product can be picked up.&nbsp;The APSX-PIM&#39;s novel approach to overmolding showcases its advantages over traditional vertical injection molding machines. Through its horizontal design, simplified maintenance, and cost-effective operation, the APSX-PIM demonstrates how it can streamline overmolding processes.&nbsp;ConclusionThe APSX-PIM challenges the status quo by offering a fresh outlook on overmolding, countering the notion that vertical injection molding machines are the sole solution. As industries evolve, embracing such advancements can lead to a more streamlined, adaptable, and cost-efficient overmolding process.

Innovations often redefine conventional processes, leading to improved outcomes.

Demystifying Overmolding: A New Approach with the APSX-PIM

Being proactive in your production can save you time and money in the long run. Investing in your own production equipment can eliminate the long lead times and high minimum order quantities that often come with relying on manufacturing vendors.Here are some steps to help you take control of your production and invest in your own equipment:<ul><li>Identify your production needs: Before investing in equipment, you must determine what equipment is necessary for your production needs. Consider the products you have and the quantity you need to produce.</li><li>Research equipment options: Once you have identified your production needs, research the available equipment options. Look for equipment that fits your budget, easy to use and maintain.</li><li>Calculate the return on investment: Before making any investment, calculate the potential return on investment. Determine how much money you could save on production costs by investing in your own equipment and compare that to the equipment cost.</li></ul>One of the best ways to take control of your production and eliminate long lead times and high minimum order quantities is by investing in&nbsp;<a href="https://apsx.com/apsx-products" target="_blank">desktop-size portable production machinery</a>. These machines offer a range of benefits, including:<ul><li>Flexibility: Portable production machinery allows you to move your production to where it's needed most. Whether you want to maximize the use of your available space, portable machinery can be a game-changer. With desktop-size machines, you can easily move them around your workspace, set them up wherever you need them, and quickly adjust your production line as needed.</li><li>Cost savings: Investing in desktop-size portable machinery can also save you money. With the ability to produce products in-house, you can eliminate the need to rely on third-party manufacturers and their associated costs. You'll also save money on shipping and handling fees, and you can reduce the costs associated with excess inventory and wasted materials.</li><li>Increased productivity: With portable production machinery, you can increase your productivity and reduce production time. These machines are designed to be efficient and effective, allowing you to produce products quickly and easily. Additionally, with desktop-size machines, you can reduce the time spent on setup and changeover between different products.</li><li>Better quality control: By producing products in-house, you have more control over the quality of your products. You can closely monitor every step of the production process and make adjustments as needed. This ensures that your products are produced to your exact specifications and you can maintain a consistent level of quality.</li><li>Competitive advantage: Finally, by investing in desktop-size portable production machinery, you can gain a competitive advantage in your industry. You can offer your customers faster turnaround times and customization options by producing parts in-house. You can also be more responsive to changing market demands and trends, which can help you stay ahead of your competitors.</li></ul>Suppose you have an industrial machine in your facility. In that case, there are several benefits to using small desktop size machinery instead of large industrial size expensive machinery for small or one-off batch production:<ul><li>Lower cost: Small desktop size machinery is generally less expensive than large industrial size machinery, making it a more cost-effective option for small or one-off orders. This can help to reduce overhead costs and improve profitability.</li><li>Space-saving: Small desktop size machinery takes up less space than large industrial machinery, making it a great option for smaller workshops or home-based businesses with limited space.</li><li>Greater flexibility: Small desktop size machinery is often more flexible than large industrial machinery, making it easier to switch between different production processes or parts. This can help to improve efficiency and reduce downtime.</li><li>Ease of use: Small desktop machinery is often easier to operate than large industrial machinery, requiring less specialized training or technical expertise. This can help reduce new operators' learning curve and improve productivity.</li><li>Quick setup and turnaround time: Small desktop size machinery can be set up and ready to use much more quickly than large industrial size machinery, allowing for faster turnaround times on small or one-off orders. This can help to improve customer satisfaction and build a reputation for quick and reliable service.&nbsp;<iframe id="650d574c5846db2c4981aad1" width="250" class="specs-iframe" height="440" src="https://wevolver.com/iframe/specs/apsx-nano-cnc-swiss-lathe?iframe=true" frameborder="0" scrolling="false" data-lf-form-tracking-inspected-kn9eq4roawkarlvp="true" data-lf-yt-playback-inspected-kn9eq4roawkarlvp="true" data-lf-vimeo-playback-inspected-kn9eq4roawkarlvp="true"></iframe></li></ul>Using small desktop machinery can provide several advantages for machine shops and other manufacturing businesses. It can help to reduce costs, save space, increase flexibility, and improve efficiency, making it a great option for small or one-off orders.In conclusion, investing in desktop-size portable production machinery is smart for any business looking to take control of its production and eliminate long lead times and high minimum order quantities. By offering flexibility, cost savings, increased productivity, better quality control, and competitive advantage, these machines can help you achieve your production goals and grow your business.

Are you tired of waiting for your manufacturing vendors to produce your parts? Do you struggle with high minimum order quantities that force you to order more than you need? It's time to take control of your production and invest in your own production equipment.

How to Take Control of Your Production and Eliminate Long Lead Times

<a href="https://www.makerverse.ai/cnc-turning" target="_blank" rel="noopener noreferrer">CNC turning</a> is a machining process that creates exact parts with cylindrical shapes, like shafts and sleeves. During this process, the turning machine rotates the material against a cutting tool controlled via a computer program. The program enables high accuracy levels, making CNC capable of everything from very simple to highly intricate parts.The design process is the first crucial step in creating functional parts for all types of <a data-hook="linkViewer" href="https://www.makerverse.ai/cnc" target="_top" rel="noopener noreferrer">CNC machining</a>. Optimizing the CAD model lowers costs, faster production, and better parts. This model generates the CAM program, which controls every cut of the CNC turning machine. Designing for manufacturability (DFM) ensures parts can be successfully machined without errors or failure.<div data-hook="imageViewer"><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1691484740124-1691484740124.png" alt="CNC turning in action" class="fr-fic fr-dii"></div><h5>Make Use of Bar Stock Sizes and Shapes</h5>Bar stock is the raw, purified material used in CNC turning. Its size and tolerance can often be advantageous when designing for screw-machine production. &nbsp;The maximum diameter should be the bar stock&#39;s diameter to conserve material and reduce machining for your part. Use standard sizes and shapes of bar stock whenever possible rather than special diameters and shapes. Easily accessible raw materials are available between 1 to 20 mm in increments of 1 mm and up to 5 mm for bigger sizes.The raw material must be at least 0.4 mm bigger if tolerances are needed at the biggest diameter.<h5>Use Standard Tools as Much as Possible</h5>You should specify standard, common sizes for holes, screw threads, slots, knurls, etc. This ensures that readily available tools and gauges can be used in production, instead of those that need to be specially made. We recommend checking out <a data-hook="linkViewer" href="https://www.sandvik.coromant.com/en-us/products/toolguide/tool-recommendation" target="_unrecognized" rel="noopener noreferrer">this tool guide</a> to follow standard processes for turning machines.<h5>Avoid Secondary Operations</h5>Your should design parts to complete on cutoff from the bar material whenever possible. If you can&#39;t avoid secondary operations, try to minimize them at least. Many features of the part &ndash; especially internal surfaces and screw threads &ndash; should be located on only one end of the part. This way, all machining can be performed before the cutoff.As many features as possible, especially internal surfaces and screw threads, should be located on one end of the part.<div data-hook="imageViewer"><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1691484739968-1691484739968.png" alt="" class="fr-fic fr-dii"></div><h5>Prevent Tool Marks</h5>While minor tool marks are often inevitable, avoiding defects like scratches or gouges is important. These affect not only the look of your part but also the mechanical properties. &nbsp;To prevent such defects, sidewalls of grooves and other surfaces perpendicular to the part&#39;s axis should have a slight draft of 0.5&deg; or more. This draft prevents tool marks from forming on the machined surface as the tool withdraws.<div data-hook="imageViewer"><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1691484739785-1691484739785.png" alt="How to avoid tool marks" class="fr-fic fr-dii"></div><h5>Use Undercuts in Only One Direction</h5>Standard tool slides in turning machines operate at right angles to the axis of the workpiece. An angular undercut, whether internal or external, is challenging to produce and should be avoided whenever possible.Annular grooves are easier to create on the part&#39;s exterior surface than an internal recess. External grooves can be incorporated into form tools. Internal recesses require tools with both axial and transverse motion. If you have the choice, design parts to contain external grooves. <div data-hook="imageViewer"><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1691484740021-1691484740021.png" alt="" class="fr-fic fr-dii"></div> <h5>Provide Space for Thread-Cutting Tools</h5>The CNC threading process cuts threads on the surface of parts. External threads should not terminate too close to a shoulder or larger diameter. There should be an area for thread relief or undercut whenever the diameter of the workpiece is less than the minor thread diameter. See the below image. <div data-hook="imageViewer"><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1691484739869-1691484739869.png" alt="" class="fr-fic fr-dii"></div><h5>Limit the Need for Deburring</h5>A burr is a rough edge or ridge to a machined part. Deburring is highly manual work that adds extra costs for each part. To avoid burrs, see the below images for some design recommendations for when screw threads intersect other surfaces.<div data-hook="imageViewer" tabindex="0"><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1691484739997-1691484739997.png" alt="" class="fr-fic fr-dii"></div><h5>Understand Knurls</h5>Knurling creates patterns on round parts for functional or aesthetic purposes. A knurled area should be narrow, and the width should not exceed the diameter.&nbsp;Knurling can&#39;t produce an exact number of teeth, so define some points to guide the producer:<ul><li>An approximate number of teeth or the general size of the knurl (coarse, medium, fine)</li><li>Type of knurl (straight, diagonal, diamond)</li><li>Use for the knurl (finger grip, appearance, press fit)</li></ul><h5>Avoid Sharp Corners</h5>Sharp corners, whether internal and external, can cause weaknesses or require the costly fabrication of tools.When a sharp corner is required, try to design it within specific limits that still fulfill the functional requirements of the part. These corners can be given a commercial corner break of 0.4 mm by 45&deg;. An inside corner can be made &quot;sharp&quot; by providing an undercut at the corner. This eliminates the inevitable radius produced by a form at this intersection.<div data-hook="imageViewer"><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1691484740282-1691484740282.png" alt="" class="fr-fic fr-dii"></div><h5>Design Spherical Ends Correctly</h5>When a spherical end is required on a CNC turning machined part, it&#39;s best to design the radius of the spherical end larger than the radius of the adjoining cylindrical portion. Designing this way eliminates the need to blend two surfaces that might not be perfectly concentric because separate tools typically form them. <div data-hook="imageViewer"><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1691484740450-1691484740450.png" alt="" class="fr-fic fr-dii"></div> <h5>Designing for Slots and Flats</h5>Slots and flats can be produced with a concave surface at the material&#39;s end or bottom, with the curvature radius the same the milling cutter&#39;s. The bottom or end can be flat by transverse feeding of the cutter. If the function of the part does not require a flat surface, allow a concave surface, which is easier to produce. <div data-hook="imageViewer"><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1691484740431-1691484740431.png" alt="" class="fr-fic fr-dii"></div> <h5>Know Where to Engrave</h5>Impression markings can be made as part of the regular operations of CNC turning machine as via milling engraving. Other positions of milled engraving require secondary operations.<div data-hook="imageViewer"><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1691484740478-1691484740478.png" alt="" class="fr-fic fr-dii" style="width: 587px;"></div><h5>Take Care with Thin Parts</h5>Your design should minimize unsupported, delicate small-diameter work whenever possible. Doing so reduces work deflection from the cutting tool. Keeping parts as short as possible helps. Short, thicker parts are easier to machine than long, thin parts, as the latter requires tailstock or steady-rest support.<h2>Designing for On-Demand Manufacturing</h2>The perfect design is a crucial step in the CNC turning process. The other important step is choosing the right place to turn your design into a finished part.MakerVerse gives you a <a href="https://app.makerverse.ai/quote/upload" target="_blank" rel="noopener noreferrer">one-stop shop platform </a>for advanced manufacturing technologies, including CNC machining and additive manufacturing. Simply upload your design, choose your manufacturing technology and material, and receive your quote with the expected lead time.If you need custom-tailored parts, <a href="https://app.makerverse.ai/quote/upload" target="_blank" rel="noopener noreferrer">we&#39;re ready to help you</a>. Our engineering and operations experts can personally assist you with your entire project.&nbsp;

cnc milling

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