CNC Machining Service
CNC Machining is an advanced manufacturing technique that involves using computer-controlled machinery equipped with precise cutting tools to shape materials like plastic or metal. These machines operate based on specific instructions encoded in computer language. They meticulously carve or remove material from a solid block, following detailed commands dictating the tool's placement, speed, and movement across designated coordinates on different axes (such as x, y, and z).
The process allows for the creation of intricate parts with exceptional accuracy and consistency. CNC machines, including milling machines (both vertical and horizontal), lathes, routers, and grinders, provide versatility in shaping components with remarkable precision. This technology enables the production of identical parts repeatedly and ensures high-quality results.
With our state-of-the-art CNC machining capabilities, our factory is equipped to handle complex designs and deliver high-precision custom parts with exceptional accuracy. Our experienced team utilizes advanced software and cutting-edge machinery to bring your unique concepts to life, offering unlimited possibilities for customization. Whether it's intricate geometries, tight tolerances, or specific material requirements, we have the expertise to meet your exact specifications and provide personalized solutions for your manufacturing needs.
CNC Machining Process
1.CNC Milling
CNC milling is a computer-controlled machining process that uses rotating cutting tools to remove material from a workpiece, resulting in the creation of custom-designed components with high precision.
How CNC Milling Works
CNC mills are highly proficient at profile cutting harder materials. Like all CNC machines, they rely on G-Code to operate, which is generated through CAM software. The G-Code provides precise instructions to the machine, dictating the tool head's movement, rotational speed, cutting depth, workpiece positioning, and other crucial factors such as speed, feed rate, and coordination. The complexity of the G-Code depends on the number of axes the milling machine possesses.
While CNC mills can still be utilized for profile cutting softer materials, they are not as cost-effective as CNC routers for this purpose. The primary distinction between these machines lies in how they handle the cutting process. CNC routers keep the workpiece stationary while directing the cutting head around it, whereas CNC mills may move both the tool head and the workpiece. As a result, CNC mills are predominantly employed in industrial manufacturing, while CNC routing is more common in lower output manufacturing, particularly for tasks involving woodworking.
CNC milling offers several advantages over manual milling, including improved accuracy, repeatability, and the ability to produce complex geometry. It is widely utilized in industries such as automotive, aerospace, electronics, and prototyping for manufacturing parts with high accuracy and efficiency.
2.CNC Turning
CNC turning is a versatile and reliable machining process for creating cylindrical components with exceptional precision, surface quality, and efficient production capabilities, suitable for a wide range of industries and applications.
Top Metal Stamping provides CNC horizontal turning service, offering the capacity to manufacture parts weighing up to 950 lbs., with dimensions of up to 44″ in length and 25″ in diameter. Additionally, we can produce small parts as slim as 1/8″ wide, adhering to precise tolerances. Our 3-axis, live tooling-equipped turning center allows us to perform various operations, such as internal and external threading, knurling, profiling, and more.
CNC Machining Materials
1. Metal:
CNC machining is widely employed for working with a diverse array of metals. It can effectively cut various metal types, from common materials like aluminum, brass, copper, stainless steel, and low-carbon steel alloys to more robust metals such as titanium and nickel superalloys like Inconel. This versatility allows CNC machines to cater to an extensive range of applications, spanning from crafting injection molds to manufacturing shafts and gears.
2. Plastics
While injection molding is the primary method for manufacturing plastic parts, CNC machining finds application in producing specific plastic components. This process caters to various materials like ABS (acrylonitrile butadiene styrene), nylon, and polycarbonate. Plastic machining is utilized for crafting valve bodies, bushings, and prototypes for injection molding assessment, allowing for verification of overall part functionality before investing in costly molding tools.
Materials commonly used for plastic machining encompass a broad range:
- ABS
- HDPE
- Noryl
- Nylon
- PC
- PEI
- PMMA (Acrylic)
- POM
- PTFE (Teflon)
- PVC
- UHMW
- ULTEM
These materials cater to various industrial needs and provide options for CNC machining of plastic components across different applications and industries.
CNC Machining surface finishes
Top Metal Stamping offers a range of CNC machining surface finishes to enhance the quality and characteristics of parts:
Polishing: Using abrasives or grinding tools, polishing removes defects and burrs, achieving a smooth, bright appearance, enhancing surface smoothness and luster.
Grinding: This method utilizes grinding wheels to enhance flatness and dimensional accuracy, suitable for minor adjustments and material removal on the surface.
Sandblasting: Projecting fine sand particles creates varied textures for aesthetic and design effects, removing roughness and achieving a uniform matte effect.
Etching: Chemical substances create specific patterns or textures, commonly used for decorative or marking purposes on metal parts.
Electrical Discharge Machining (EDM): Employing electrical sparks creates small pits and recesses, improving surface quality and increasing roughness.
Coating: Applying special materials like chrome, nickel, or zinc plating enhances protection, wear resistance, and corrosion resistance.
Anodizing: This electrochemical process forms a protective oxide layer on metal surfaces, providing corrosion resistance and increased hardness.
Electropolishing: An electrolytic process improves surface smoothness and uniformity for a glossy, refined finish.
These surface finishes offer various benefits, from aesthetics to functional improvements, catering to diverse design requirements and material characteristics.
How Much Does CNC Machining Cost?
The cost associated with CNC machining a part is influenced by several key factors:
Material Selection: The choice of material significantly impacts costs. Some materials, like aluminum, are more cost-effective to machine compared to harder metals such as Inconel, which result in increased tool wear and slower cutting speeds, elevating machining costs.
Complexity of Design: Parts with intricate or complex features tend to be more expensive to machine. Components with elaborate surface shapes or intricate details will require more time and precision, driving up the machining costs compared to simpler designs.
Dimensional Tolerances: Tighter dimensional tolerances increase the complexity and precision required during machining, thereby raising costs. Specifying excessively tight tolerances on non-critical features can inflate machining expenses without necessary benefits.
Surface Finish Requirements: Achieving mirror finishes or specialized surface textures demands additional tooling and machining strategies. This requirement leads to longer machining times, thereby increasing overall costs.
Production Volume: The scale of production significantly influences per-part costs. Low-volume production typically incurs higher costs per part due to setup and programming expenses spread across fewer units. Conversely, larger production runs benefit from economies of scale, reducing per-part costs.
In essence, the cost of CNC machining a part is shaped by material characteristics, design intricacies, precision demands, surface finish requirements, and production volume. These factors collectively determine the overall expense involved in CNC machining a specific component
Why Choose Us for Custom CNC Machining?
Access instant quotes for customized metal and plastic machined parts through our cutting-edge Online CNC Machining Service. Experience swift prototyping and rapid production, ensuring your prototypes and manufactured parts are ready within a short turnaround time. Count on our commitment to delivering the highest quality, backed by ISO 9001:2015 and ISO 16949 certifications, affirming our adherence to stringent industry standards. Collaborate with us to optimize your projects and leverage superior customer service. Reach out now to commence your machining requirements with precision and efficiency. Achieve precision, quality, and cost-effectiveness at any production volume.
Manufacturing& Delivery Capability
Equipped with advanced equipment and skilled operators, our factory has high production capacity, enabling efficient and scalable CNC machining for small to large batch sizes. We ensure on-time delivery of CNC machining projects, ensuring prompt delivery and customer satisfaction.
Design Flexibility&Material Expertise
Our CNC machining capabilities offer design flexibility, allowing us to produce complex geometries, intricate features, and custom parts, providing innovative solutions for various applications. We excel in handling a wide range of materials, including metals, plastics, and composites, leveraging our expertise to select the most suitable materials for each project, ensuring outstanding performance and quality.
Quality Assurance
Following strict quality assurance protocols, our factory conducts comprehensive inspections and tests at each stage of the CNC machining process, guaranteeing the highest quality and reliability of the finished products. With state-of-the-art CNC machines and meticulous quality control measures, we ensure precise and consistent results, meeting the highest industry standards and exceeding customer expectations.
Technical Expertise
Our team of experienced engineers and technicians possesses extensive knowledge and expertise in CNC machining, providing valuable insights, technical support, and guidance to optimize designs and improve manufacturability. Through optimized processes, material utilization, and automation, our factory offers cost-effective CNC machining solutions, helping customers achieve their production goals within budget.
Key Features
- Skilled Team with Extensive Expertise
- State-of-the-Art In-house Equipment
- Competitive Pricing in the Industry
- Collaborative Approach & Proactive Design for Manufacturability (DFM)
- Advanced Capability for High-Complexity Machining
- Leading Industry Turnaround Times
CNC Machining Advantages:
The subtractive process of CNC machining offers numerous advantages for both prototyping and production parts.
Precision and Accuracy
Versatility in Design and Production
Efficient and Rapid Manufacturing
Customization to Meet Unique Specifications
Consistent Quality and Reliability
CNC Machining Capability:
Fast lead time for most custom CNC parts.
Various surface finishes are available.
Tight tolerances. Within +/- 0.002 in. (0.05 mm) for metal parts.
CNC machining limitations:
Specialized Skills Required: Operating and programming CNC machines demands specialized expertise, which can be costly to acquire. Skilled personnel are essential, and their training or hiring comes with a financial investment.
High Cost of Equipment: CNC machines require high precision and rigidity, leading to substantial costs. Investing in CNC equipment necessitates a thorough assessment of the current workload and a careful consideration of the potential return on investment to justify the expense.
CNC Machining Applications
CNC machining is extensively utilized in aerospace, medical, and automotive industries for its ability to produce accurate parts using production-grade materials efficiently. Typical CNC parts include:
- Housings and Enclosures
- Brackets
- Manufacturing Fixtures
- Gears and Bearings
- Internal Mechanical Components
- Medical Instruments