Small Batch CNC Machining: All You Want to Know

Small batch CNC machining comprises manufacturing the same components through the CNC machining process in small quantities which may range somewhere between one to a few hundred. If you are looking forward to learning about small-batch CNC machining, this guide below contains detailed information so let's explore.

Small Batch CNC Machining Explained

Small batch manufacturing is a CNC machining process that comprises manufacturing components in small volumes that are equipped with a combination of customization and precision.

Small-batch CNC machining focuses on small quantities and ensures that every piece meets strict standards of quality. Small batch manufacturing provides projects with precision, customization, and intricate designs.

Small Batch CNC Machining Process

Small batch CNC machining processes are equipped with various techniques, some of these processes are as follows:

CNC Turning

CNC turning is a small batch manufacturing process consisting of rotating workpieces and the cutting tool is stationary. The process is carried out on CNC lathes and helps create cylindrical parts precisely. It is suitable for materials like brass and aluminum. It helps create components that require tight tolerance and accuracy.

CNC Milling

CNC milling process is a widely opted process of machining for small batch production, it involves removing materials that comprise rotary tools for cutting. These machines move along multiple axes to help create components with complex features. It can create small batches with flexibility and precision with detailed features.

CNC Drilling

CNC Drilling involves the creation of holes in the workpiece, this process is performed using CNC drilling tools and helps create accurate holes. This process works for a wide material range consisting of plastics and other hardened materials.

EDM Machining

EDM stands for Electrical Discharge Machining and offers the manufacturing of small batches by using electrical spikes to erode the material. This process helps in creating components that are made using hard materials and require intricate designs. It uses machines that have electrodes and thin wires so that precise cuts are achieved.

Surface Grinding

Surface grinding is a process that helps in achieving finely finished small batches of components through CNC machining. This process comprises using an abrasive wheel that keeps on rotating and adds smoothness to the workpiece. It offers uniformity and accuracy in the final part.

There are versatile materials that can be used for manufacturing components using surface grinding and creating specialized tools.

What Materials Are Commonly Used in Small Batch CNC Machining?

The small batch manufacturing process through CNC machines comprises the following materials used for manufacturing components.

Aluminum: It is known for its strength and lightweight which makes it popular for automobile and aerospace components. It is easy to machine and offers thermal conductivity.

Stainless Steel: It offers corrosion resistance and is used in the medical industry and manufacturing equipment used in food processing. It offers integrity even in harsh conditions.

Brass: Brass is known for its aesthetic appeal and it is mostly used in electrical components and offers excellent electrical conductivity and corrosion resistance.

Titanium: It has a high strength-to-weight ratio and excellent corrosion resistance due to which it is suitable in medical and aerospace applications offering superior durability.

Copper: Copper offers seamless electrical conductivity and is used in electronic applications, it is also used in heat exchangers.

Tool Steel: It is used for its hardness and is used in producing molds and tools, it holds the cutting edge very well.

Carbon Steel: It offers machinability and durability, and it is used in the automobile industry.

Tungsten: Tungsten has a high melting point and high density, hence it is used in applications comprising extreme resistance to heat like military and aerospace.

Nickel Alloys: These alloys are selected for corrosion resistance and high temperature because nickel alloys are suitable for harsh applications like chemical plants.

Plastics: Plastics are commonly used in various applications which comprise lightweight, versatility, and corrosion resistance. ABS is used in prototyping and for applications having high temperatures use PEEK.

Benefits of Small Batch CNC Machining

Small batch machining comprises various benefits and some of these are as follows:

Cost-Effectiveness

Small batch manufacturing helps minimize the cost of initial setup and when small quantities are produced the need for large inventory decreases. It also helps in reducing the storage cost and the risk of obsolescence.

Flexibility

Low-volume CNC machining is a flexible process. It allows for rapid production in small batches and enables immediate response to changing trends. You can also modify the designs in between batches without incurring much of the cost.

High Precision and Quality

CNC machines have the capability of producing components that are highly precise and consistent. These components are equipped with superior quality and high tolerance. Also, the process being automated offers consistent quality for all the units that have been produced.

Efficiency

CNC machining is an efficient process because it helps in reducing time as well as cost by optimizing the production process.

Adaptability

Small-scale CNC machining is suitable for prototyping and helps create small-scale testing so that any design improvements can be catered to in the future. Moreover, adapting to fluctuations becomes easy for small-scale production.

Limitations for Small Batch CNC Machining

Along with benefits, there are some limitations associated with small-batch CNC machining, some of these limitations are as follows:

High Cost Per Unit

Large batches offer economies of scale as it helps to reduce their per-unit cost whereas in the small batches, the cost per unit is very high due to the operating expenses and setup costs.

Initial Cost and Setup Time

Every batch of production may need a unique setup which causes a lot of cost and time to be spent on parts that are complex.  Moreover, the cost of initial fixtures and tooling also add up causing the overall process to be expensive for such a small run.

Constraints of Material

CNC machining minimizes waste but still when compared to the larger batch processing the material wastage is high and also purchasing material in small quantities is expensive compared to the high quantities.

Downtime of Machine

Regularly changing the batches causes machine downtime which impacts productivity. Also, the frequent stops may cause wear and tear on the machinery requiring frequent maintenance.

Lack of Scalability

Small batch CNC machining is not suitable for producing high-volume and it is because of the cost and time constraints. In case the quality demand increases, the sudden scaling up of the production is not possible.

Tips to Small Batch CNC Machining

Some important  tips for small-batch machining comprise the following:

• Reduce complexity in the component design where possible as it helps to reduce the cost and machining time.
• Try to manufacture standard components so that the need for custom tooling now and then could be eliminated for the small batches.
• Tight tolerance increases time as well as cost so opt for tight tolerance only where they are needed for functionality.
• The parts which are modular usually have simplified assembly and machining, try to design such parts.

Applications of Small Batch CNC Machining

There are diverse applications of small-batch CNC machining and some of these are as follows:

Aerospace

The aerospace industry demands precision in the components, the small batch CNC machining may offer components that are precise in aerospace, reliability and tight tolerance are crucial hence CNC machining offers that. The components of aerospace manufactured using small batch CNC machining are landing gears and turbine blades.

Automotive

Automobile parts that need precision, durability, and flexibility are manufactured under low-volume CNC machining. The custom parts and their prototypes for automobiles are manufactured which include engine components and gears. In cases where any specific request of a custom is required to be fulfilled for an automobile, small-batch CNC machining can be suitable.

Medical

Custom medical devices like surgical tools and implants are such components where accuracy and quality are crucial. Small batch production allows the creation of custom and high-precision components that cater to the medical industry. Patient-specific implants can be manufactured through small-batch machining.

Electronics

Electronic manufacturers commonly use small-batch machining for the production of components used in electronic items. These components may consist of heat sinks, connectors, and casings. Also, a startup or a new model of any appliance or gadget may need a prototype before the final product can be manufactured.

Conclusion

Small batch CNC machining prevails in various applications and since you have gone through this guide above you must have familiarized yourself with a lot of important aspects. If you are looking for small batch CNC machining for your applications get in touch with DEK. You can have custom components manufactured according to your specifications in low volume.

FAQs

How does small-batch CNC compare to 3D printing?

Small batch machining offers better surface fishing and higher precision compared to 3D printing. 3D printing is mostly opted in complex geometrical shapes and rapid prototyping.

What Is the Cost Aspect of Small Batch Machining?

Small-batch CNC machining costs are higher on a single unit because of the material, labor, and setup costs. Also, due to frequent changeovers, the machine downtime and maintenance cost increase.

What types of parts are suitable for low-volume CNC machining?

Small batch machining is suitable for customized components, short-run production, and prototypes. It is suitable for applications that need tight tolerances and complex geometries.

What are low-volume manufacturing methods?

The low-volume methods of production consist of 3D printing, CNC machining, and injection molding.