How to reduce CNC Machining cost
CNC machining is a common and cost-effective method of creating precise, durable parts and components. To increase efficiency, it is essential to understand the different factors that can affect your CNC machining operations.
Following those tips and carefully considering the factors influencing CNC machining costs, you can optimize your design and reduce project costs significantly. With careful planning, effective strategy, and a focus on efficiency, you can realize significant cost savings with CNC machining.
If you’re looking to optimize your design and reduce project costs, this article is for you. It provides extensive tips and proven strategies to help you save money.
Table of Contents
What factors determine the cost of a CNC part?
Several key factors can affect the cost of a CNC part, including below:
- Materials cost;
- Setup time;
- Machine downtime;
- The complexity of the design;
Materials cost
There are a variety of different materials that can use for CNC machining, each with its own set of advantages and drawbacks. Some materials may be more cost-effective than others, and certain materials may be more suitable for specific design requirements or manufacturing processes. Factors such as material strength, hardness, thermal properties, ease of machining, and cost should be considered when selecting materials for CNC parts.
Setup time
A CNC part’s cost depends mainly on time required to complete machining operations. Setup time is one factor that can significantly impact overall machine efficiency and, therefore on, the cost of production.
Machine downtime
One crucial factor that can affect the cost of a CNC part is machine downtime. When a machine is down for maintenance, repair, or any other reason, it cannot produce parts. This results in lost productivity and increased costs due to lower production rates and/or higher labor costs.
The complexity of the design
One of the main factors that can affect the cost of CNC machining is the complexity of the design. More complex parts require more time and effort to machine, resulting in higher prices. Factors contributing to a complicated part include intricate or tight tolerances, multiple materials and/or finishes, and more minor features such as slots and grooves.
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How to reduce CNC machining costs?
One of the critical factors that impact the price of CNC machining is understanding what drives these costs. Optimizing your design to minimize waste and reduce material usage can significantly lower your machining budget.
Here are the tips to reduce CNC Machining costs:
- Avoid expensive Materials
- Avoid complex design
- Avoid Tight Tolerances
- Avoid Thin Walls and Features
- Avoid surface texting
- Avoid Having Multiple Finishes
- prioritizing machine setting
- Provide Relief to Corner Pockets
- Order Larger Quantities
- Considering Outsourcing
Avoid expensive Materials
To help you stay within your budget, we’ve gathered a variety of metals and plastics, each with its own set of attributes, costs, and machining requirements. Some needed to consider when selecting a material are:
If you are looking for a material that is easy to machine, consider using softer metals like aluminum 6061 or mild steel.
Softer metals are less expensive to machine because they cut more efficiently, resulting in less time and effort spent on the machining process. Additionally, these materials are typically less costly than harder ones, as they require less expensive tools and are less likely to break or wear down your devices.
If you need a more machinable but relatively soft material, consider using mild steel instead of aluminum 6061. While mild steel may be more challenging to work with at times, it can ultimately save you time and money in the long run. So if you are looking for a cost-effective material for your next project, consider using softer metals like those mentioned above.
Avoid complex design
When designing machined parts, it is essential to keep things simple and avoid complex designs that may require additional support structures or fasteners. This will increase costs due to the need for supplemental materials and labor and lead to problems with stress and movement in the finished part. If you need a piece difficult to machine, it may be better to break it into multiple components and use fasteners to assemble them. While this may increase assembly costs, it can help reduce issues with stress, movement, and other challenges in the finished part. Ultimately, achieving the ideal design for your machined parts requires careful consideration of all factors involved.
It is essential to avoid making parts that are too complex or include excessive material, as this can lead to issues with work holding or machining. If your design becomes difficult to handle, break the parts into multiple components and use fasteners to assemble them. While this approach can help reduce costs and simplify production, it may also add complexity. Ultimately, the best way to ensure that your parts are accessible to a machine is to consider their design before beginning production carefully.
Avoid Tight Tolerances
When designing a part, it is essential to consider the use of tight tolerances carefully. While certain features and surfaces on a position may be critical to its function, many others are less significant. By assigning numerical values only to those mission-critical components and leaving other features controlled by the model, you can help minimize costs and ensure optimal performance.
Additionally, it is crucial to choose a single datum point or reference surface when defining tolerances and then dimension the rest of the part accordingly. At okdor, our engineers work closely with customers to determine appropriate tolerances based on various factors, including function, material type, and production method. With meticulous attention to detail and precision, we can deliver high-quality parts that meet our customers’ exact specifications.
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Avoid Thin Walls and Features
Thin-wall geometries are a common feature of many machined parts, but they can be especially prone to breakage and warping during the machining process, Which means they are expensive. Suppose your part design includes features that are 0.020 in. or smaller. In that case, it is crucial to be cautious when machining these areas and take steps to ensure that your part is as sturdy and durable as possible, which may involve beefing up the thin walls with extra material or choosing more robust design features for your custom parts. By being mindful of these considerations, you can help ensure that your machined parts are safe, reliable, and effective.
Avoid surface texting
Text engraving is a labor-intensive process that may only be necessary for some machined parts.
One that you should avoid if possible Typically, a ball end mill is used to create text on the surface of a part by tracing the desired letters, numbers, or symbols in CAD software. While this can give your interest an attractive and polished look, it may be more appropriate for injection-molded parts, where the additional machining time can be more easily absorbed due to higher part volumes.
Avoid Having Multiple Finishes
Regarding surface finishes for your parts or components, it is essential to avoid using multiple finishes or textures. Mixing and matching different finishes can add unnecessary cost and complexity to the manufacturing process. For example, requesting anodized and the chem film finishes on a part may require additional processing steps. Similarly, specifying a smooth finish in one area and a bead blast finish in another can also lead to complications.
To minimize costs and ensure a smooth, uniform surface for your parts or components, it is best to leave the finish open or request a consistent, uniform finish. If you are still determining which finish would be most appropriate for your part, it may help to discuss your needs with your project manager or manufacturer. With their expertise and experience, they can help you select the right finish for your needs.
Prioritizing machine setting
One strategy for optimizing machining speed and accuracy is using advanced technologies like 5-axis CNC or high-power lasers. These cutting-edge technologies offer several key benefits, including increased production efficiency and reduced costs. They can help you maximize your process by allowing you to reduce setup times and optimize tool paths, ultimately boosting your overall machining efficiency. Additionally, utilizing these advanced technologies can achieve greater precision and control over your machined parts, resulting in a higher-quality finished product. To take advantage of all the benefits that advanced technologies offer, it is crucial to work closely with an experienced supplier who can ensure that you are selecting the right solution for your needs. By taking these steps, you can prioritize machining speed and accuracy to increase production efficiency and reduce costs.
Provide Relief to Corner Pockets
If you need to create corners with a small radius, there is a better solution than relying on EDM or multiple flat plates. By creating reliefs in the corners of your pocket, you can achieve sharper corners without costly and time-consuming machining techniques. Using an end mill that is only 0.031 inches in diameter, you can cut a corner radius of just 0.016 inches, much sharper than the typical radius found on corners of machined parts. However, this approach can be slow and delicate, requiring precision milling techniques to achieve your desired results.
Consider using larger end mills and increasing material removal rates to get the most out of your machining projects. And that can significantly reduce the time and cost of machining sharp corners while achieving the desired results. Additionally, you can create even deeper pockets than steel parts by choosing materials like aluminum or plastic, making this an ideal option for various applications. So, to save time and cost while creating sharp corners, consider using reliefs to achieve your desired results.
Order Larger Quantities
One way to achieve greater cost-efficiency during production is to order larger quantities of the same part. This allows the CNC machine to run more smoothly and efficiently, resulting in lower costs per piece. Whether you are producing small or large amounts, CNC machining can be an effective and cost-efficient solution for your manufacturing needs.
Considering Outsourcing
Outsourcing some or all of your machining needs to a trusted service provider can offer many benefits, including cost savings and increased production efficiencies. This can allow you to focus on more strategic activities while mitigating the risks associated with having an in-house manufacturing operation. A reputable service provider will notice your unique needs and goals and tailor a custom solution to meet those needs. Whether you need help with machining large parts or complex assemblies, this service provider can provide the support you need to achieve your goals while minimizing costs.
Conclusion
Many factors can impact the cost of CNC machining, and understanding these can help you reduce your machining budget. Some key considerations include avoiding expensive materials, minimizing waste, reducing material usage, and avoiding complex or tight tolerances. Additionally, it is vital to prevent thin walls or features, avoid textured surfaces, and avoid having multiple finishes. Other important considerations include prioritizing machine settings, providing relief to corner pockets, ordering larger quantities, and considering outsourcing. By following these tips, you can reduce the cost of your CNC machining projects and get the most value from your machining budget.
Frequently asked questions
One way to prevent thin walls or features when using CNC machining is to avoid creating these features in the first place. This can include carefully planning your design to minimize these features or ensuring that you have sufficient material thickness when making them. Additionally, it is vital to use proper machining techniques and settings to ensure that your parts and features can withstand the stresses of CNC machining.
Generally speaking, more significant parts and more complex designs require more time and materials to machine, which results in higher costs. To control your CNC machining costs, working with a manufacturer with the experience and expertise to machine your parts efficiently and effectively is essential. Additionally, it’s often helpful to work with an engineer or project manager who can guide design improvements that reduce machining time and costs.
One way to minimize waste and material usage during CNC machining is to be selective about your materials. This can include choosing lower-cost materials or using less material than you typically would. Additionally, you can minimize waste by reducing the material removed during machining and carefully managing your scrap materials.
The materials used in a CNC machining process can significantly impact the cost of the final product. The material’s type, quantity, and thickness will affect how much a machine costs. Lower-grade materials like aluminum or brass are generally cheaper than more complex or specialized materials like titanium or ceramics. Additionally, thicker metals will cost more to machine, as will premium materials that require specialized tooling and cutting techniques to process effectively. Ultimately, the cost of your CNC machined parts depends on several factors, so it is essential to carefully consider all these different variables when developing your production specifications.
One of the best practices for minimizing CNC machining costs is carefully selecting your materials. Choosing materials that are easy to machine can help reduce overall production costs while ensuring high-quality parts. Another best practice is to use modern manufacturing techniques and equipment, such as computer numerical control (CNC) machines and advanced tooling. Additionally, you can reduce costs by outsourcing your machining work to a reputable and experienced machinist. By following these best practices, you can minimize CNC machining costs while still producing high-quality parts.
