{"id":6689,"date":"2024-12-23T23:39:33","date_gmt":"2024-12-24T07:39:33","guid":{"rendered":"https:\/\/richconn.com\/?p=6689"},"modified":"2024-12-23T23:39:35","modified_gmt":"2024-12-24T07:39:35","slug":"small-batch-cnc-machining","status":"publish","type":"post","link":"https:\/\/richconn.com\/small-batch-cnc-machining\/","title":{"rendered":"Small Batch CNC Machining: Everything You Should Know","gt_translate_keys":[{"key":"rendered","format":"text"}]},"content":{"rendered":"\n

One of the most cost effective ways of making precision components is small batch CNC machining. This presents faster turnaround times and flexibility for design changes compared to mass production. In this blog post we are going to cover its different types, advantages and how it\u2019s used in various sectors.<\/p>\n\n\n\n

What is Small-Batch CNC Machining?<\/h2>\n\n\n\n
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Simply put, small batch CNC machining procedures involve using machines, controlled by computers, to create small batches of parts. It has unusually short turnaround times, outstanding precision and is easily adaptable to design changes. The method is very good at producing complicated, custom components with strict tolerances.<\/p>\n\n\n\n

Types of Small-Batch CNC Machining<\/h2>\n\n\n\n

CNC Milling<\/h3>\n\n\n\n
\"CNC<\/figure>\n\n\n\n

CNC milling<\/a> refers to a process, where a fixed workpiece is shaped using a rotating cutting tool. The machine travels in multiple axes to generate precise (+\/-0.01 mm) complex shapes. This flexible process is excellent for making slots and flat surfaces on small batch components in many industries.<\/p>\n\n\n\n

CNC Turning<\/h3>\n\n\n\n
\"CNC<\/figure>\n\n\n\n

CNC turning<\/a> is the process of making cylindrical parts using computer guided lathes. The static cutting tools remove material from the workpiece as the workpiece rotates to reach tight tolerances down to \u00b10.01 mm. It\u2019s great at making symmetrical components such as bolts, shafts and custom cylindrical components with outstanding surface finishes.<\/p>\n\n\n\n

Wire EDM Machining<\/h3>\n\n\n\n
\"Wire<\/figure>\n\n\n\n

In wire EDM<\/a> the conductive material is cut using a thin electrically charged wire (usually 0.004″ to .012″ diameter) by controlled electrical discharges. This method is common in small batch CNC machining when parts require detailed dimensions and narrow tolerances. Due to minimum material waste, this process is suitable for parts like thin walls, delicate contours or fine holes.<\/p>\n\n\n\n

CNC Drilling<\/h3>\n\n\n\n
\"CNC<\/figure>\n\n\n\n

In CNC drilling computer controlled machines drill accurate holes in workpieces. The process works well for small batch CNC machining because it allows quick creation of holes with different sizes and depths. CNC drilling is versatile for industries that require high precision components including aerospace and electronics.<\/p>\n\n\n\n

Surface Grinding<\/h3>\n\n\n\n
\"Surface<\/figure>\n\n\n\n

Surface grinding<\/a> is the process that uses a rotating abrasive wheel to remove controlled amount of material from a work piece, to produce an ultra-precise flat surface. It produces smooth surfaced, close dimensioned parts like metal plates, precision jigs and tool parts in small-batch production.<\/p>\n\n\n\n

Sinker EDM Machining<\/h3>\n\n\n\n
\"Sinker<\/figure>\n\n\n\n

Sinker EDM uses electrical discharges between a workpiece and a shaped electrode for making complicated three dimensional (3D) cavities. It’s used to make complex cavities, like pockets or grooves, and complicated features such as tapered holes or sharp enclosed corners. In particular this method is excellent for tool steels, exotic alloys or hardened steels such as Inconel<\/u><\/a>\u00a0and titanium.<\/p>\n\n\n\n

3 Axis, 4 Axis, and 5 Axis CNC Machining<\/h3>\n\n\n\n
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The complexity and precision of multi axis machining vary. 3 axis uses three linear axes, 4 axis adds a rotational axis and 5 axis<\/a> has two additional rotational axes for machining intricate shapes and undercuts in one setup. 4 axis and 5 axis machining cuts down on setup times in small batch manufacturing.<\/p>\n\n\n\n

Materials Most Used in Small-Batch CNC Machining<\/h2>\n\n\n\n

Stainless steel<\/em><\/h3>\n\n\n\n
\"Stainless<\/figure>\n\n\n\n

It is an outstanding corrosion resistant metal and has great tensile strength<\/u><\/a>\u00a0as well. When making parts that need to function in harsh conditions, CNC machining operators often pick stainless steel<\/u><\/a>.<\/p>\n\n\n\n

Brass<\/em><\/h3>\n\n\n\n
\"Brass<\/figure>\n\n\n\n

Brass<\/a> is the best material to be used in small batch CNC machining because of its high thermal conductivity of 115 W\/m-k and outstanding machinability<\/u><\/a>.<\/p>\n\n\n\n

Aluminum<\/em><\/h3>\n\n\n\n
\"Aluminum<\/figure>\n\n\n\n

For small batch CNC machining, aluminum alloys<\/u><\/a>\u00a0are broadly used due to their good resistance against corrosion, machinability and good strength-to-weight ratio.<\/p>\n\n\n\n

Mild steel<\/em><\/h3>\n\n\n\n
\"Mild<\/figure>\n\n\n\n

Mild steel, also known as low carbon steel (0.05\u20130.25%), is a material that has good ductility, weldability and machinability. In different manufacturing processes, it is a cost effective material and has good strength to weight ratio.<\/p>\n\n\n\n

Tool steel<\/em><\/h3>\n\n\n\n
\"Tool<\/figure>\n\n\n\n

Unlike mild steel, tool steel is very hard, wear resistant and can be heated to high temperatures. It is used in small batch machining because of its ability to hold performance and form in high temperature and stress conditions.<\/p>\n\n\n\n

Alloy steel<\/em><\/h3>\n\n\n\n
\"Alloy<\/figure>\n\n\n\n

The alloy steel consists of nickel, molybdenum and chromium to give the alloy its improved properties. It exhibits tensile strengths up to 655 MPa and impressive wear resistance, and excel in high stress operations.<\/p>\n\n\n\n

PEEK<\/em><\/h3>\n\n\n\n
\"PEEK<\/figure>\n\n\n\n

Due to PEEK\u2019s high thermal stability (up to 260\u00b0C) and strength to weight ratio, PEEK is suitable for small batch CNC machining. This material is used to produce prototype automotive parts and custom aircraft bearings<\/u><\/a>.<\/p>\n\n\n\n

Nylon<\/em><\/h3>\n\n\n\n
\"Nylon<\/figure>\n\n\n\n

Nylon has excellent wear resistance, and high tensile strength (up to 12,000 psi). It has dimensional stability over a temperature range from -40\u00b0C to 100\u00b0C. The low friction coefficient and self-lubricating properties of nylon make it a good material for high wear components.<\/p>\n\n\n\n

POM<\/em><\/h3>\n\n\n\n
\"POM<\/figure>\n\n\n\n

Polyoxymethylene (POM) is plastic with outstanding wear resistance and dimensional stability. It is a high stiffness, self-lubricating material suitable for small batch precision components.<\/p>\n\n\n\n

PTFE (Teflon)<\/em><\/h3>\n\n\n\n
\"PTFE<\/figure>\n\n\n\n

PTFE has a very low friction coefficient (0.05\u20130.10) and excellent chemical resistance. Because of its ability to operate in harsh environments and its non-stick properties, PTFE is valuable in small batch manufacturing.<\/p>\n\n\n\n

ABS<\/em><\/h3>\n\n\n\n
\"ABS<\/figure>\n\n\n\n

This plastic is versatile and has modulus of elasticity of 2600 MPa and tensile strength of approximately 40 MPa. ABS is used for many electronics enclosures and consumer products because of its mechanical strength.<\/p>\n\n\n\n

Polycarbonate (PC)<\/em><\/h3>\n\n\n\n
\"Polycarbonate<\/figure>\n\n\n\n

Polycarbonate is well known for its clarity (refractive index 1.548) and unparalleled impact resistance (250 times stronger than glass). Due to its high heat resistance to 140\u00b0C and dimensional stability, it is well suited for precision small batch components.<\/p>\n\n\n\n

HDPE<\/em><\/h3>\n\n\n\n
\"HDPE<\/figure>\n\n\n\n

HDPE has a great strength-to-weight ratio, as well as chemical resistance and tensile strength of 38 MPa. Most of the time, is used in small batch production of special chemical containers and medical parts.<\/p>\n\n\n\n

Benefits of Small Batch CNC Machining<\/h2>\n\n\n\n