Low Volume CNC Machining: Pros, Design Tips and Applications
CNC machining is a primary manufacturing process, and many applications utilize it. At one point, where it is meant to offer production of high-volume parts, the low-volume CNC machining is also highly anticipated.
If you want to learn everything about small-batch CNC machining and how it works, the guide below is for you. So, let's read.
What is Low Volume CNC Machining?
Small run CNC machining is opted for to produce components in a small volume using the computer numerical control process. Every business doesn't need high-volume components, and some businesses need small batches.
Moreover, the production of components in small batches is a cost-effective method that does not require any expensive tooling. It is also suitable for the prototyping process.
Pros of Low Volume CNC Machining
The low-volume Обработка на станках с ЧПУ process comes with ample benefits, and some of these benefits are as follows:
- Low-volume CNC machining offers design flexibility, and it is easier to identify the flaws in the design and make adjustments at a very low cost.
- Low-volume production helps to manufacture high-quality components quickly, and these parts are even floated in the market in a short time.
- The time of launching the product in the market is shorter, the cash flow is improved as the sales are driven quickly, and revenue is generated in less time.
- Small batch manufacturing offers a bridge between full-scale goods production and prototyping.
- The quality of the parts produced in low-volume manufacturing is high. They are of excellent surface finish and tight tolerance, as these machines offer high precision.
How To Optimize Design to Save Cost on Low Volume CNC Parts?
In order to save the cost on low-volume CNC components, there are different ways you can optimize the design and make the most of it. Some of these ways are as follows:
Use Simple and Standard Designs
When manufacturing low-volume CNC machine components, keep them as simple as possible; complex shapes need expensive systems and manual positioning. Hence, it is suggested that designs that involve less tight tolerances and less complex shapes be selected.
Optimize Design for Manufacturability (DFM)
You can also optimize the design for manufacturing, as it helps to create components that are easy to machine. Moreover, the capability of the machine should be taken into consideration when manufacturing components using small-batch production.
Use Standard Tools and Fixtures
When manufacturing limited components, do not go for custom fixtures and tools. Instead, opt for standard tools as they are available easily and are also affordable.
Optimize Material Selection
Choosing materials that are not the right ones ends up costing more in the manufacturing process. Hence, when producing components in the short run, make sure to select materials that are highly machinable and suitable for the application. Also, try to balance the cost of the material and choose an affordable one.
Consider the Cost of Finishing
Most of the components require secondary processing after the machining has been done. These secondary processes consist of engraving, polishing, and anodizing. Hence, unless the secondary processes are very crucial, do not opt for them as they will add to the cost.
Consider Manufacturing and Assembly Processes
The process of manufacturing and assembling should be simplified, and it is suggested to opt for automation. When the process of assembly is carried out manually, it adds to the cost. Also, a single part manufacturing is a suitable process because it eliminates the need for assembling the component.
Reduce Waste
Reduction in waste also helps to cut down the cost of CNC machining. Hence, make sure to create designs that involve minimal waste.
Applications of Low Volume CNC Machining
Prototyping and Product Testing
Low-volume CNC machining is used for product development. It also creates prototypes for design validation and performance testing. There are various choices of materials that can be opted for, and designs can be changed very quickly when any defects are highlighted.
Custom Parts for Specialized Industries
Customized components for some special industries can be manufactured using low-volume CNC machining, and some of these industries are as follows:
Медицина
In the medical industry, device manufacturing requires small batches of different medical tools and devices.
Автомобили
The automobile industry considers low-volume production of components that are meant for luxury vehicles, or when they want to test any part for cars and need a prototype.
Аэрокосмическая промышленность
Highly precise parts of aircraft, like engine parts and airframes, are manufactured using low-volume CNC machining.
Precision Molds
Precision molds used in the process of injection molding are customized in different shapes and sizes and are manufactured in small quantities. Hence, low-volume CNC machining caters to such production.
Low Volume vs. Mass Production CNC Machining
When low-volume production is compared with mass production using CNC machining, some of the differences are the following:
- Low-volume CNC machining is meant to produce small batches of hardly a couple of thousand components. Meanwhile, mass CNC machining produces millions of parts.
- Large-scale manufacturing requires automated machining and expensive tools so that a high volume of parts can be handled. Meanwhile, low-volume production involves the use of limited machines and tools.
- Low-volume machining takes less time, whereas mass production needs more time as the production volume is high.
- The cost of initial setup is high in mass production, but as the volume of production increases, the cost per part decreases. Whereas in low volume production, the price per part is high as free units are produced.
- Low-volume production allows quick customization, and every part can be micromanaged. Whereas, in high production volume, customization is not feasible.
Other Low Volume Manufacturing Processes
Apart from CNC machining, there are some other processes, some of which can be chosen for the purpose of low-volume production. These processes are discussed below.
Литье под давлением в небольших объемах
Injection molding is chosen for manufacturing components by injecting the molten plastic into the molds. This process is mostly for plastic components, and small volumes of caps, enclosures, and other housings are manufactured through it.
Low Volume 3D Printing
3D-печать is also a manufacturing process that creates components in the form of layers using materials like metal, resin, or plastic. It can create parts that have complex shapes or are prototypes.
Choose DEK Small Batch CNC Machining Services
When it comes to managing small batch parts using CNC machining, we at DEK can offer you cost-effective production services. We specialize in the CNC machining process, and our expert team can design and manufacture these components with high accuracy and precision.
Заключение
The guide above discusses in detail the low-volume manufacturing of components for different applications. It even discusses how you can optimize the cost of production. So, for your next project, consider these points.
Вопросы и ответы
What are the best materials for low volume CNC machining?
The choice of material is dependent on the application. However, the materials that prove to be compatible with low-volume CNC machining are PEEK, ABS, brass, aluminum, steel, etc.
What’s the ideal quantity for low-volume CNC machining?
The ideal quantity of low-volume CNC machining varies from manufacturer to manufacturer. Generally, some manufacturers prefer it to be between 1 to 100, and some prefer it to be around 1000.
How long does it take to finish low volume CNC parts?
The determination of lead time is based on the number of parts needed and how complex they are. Sometimes, it may take as little as one day, and sometimes a week.
