Low-volume or small-batch CNC machining involves the manufacture of products or parts in small quantities, typically ranging from 10 to 1,000 pieces. This method helps manufacturers reduce production costs. In addition to cost savings, producing on a small scale allows for easier design changes without incurring significant losses.
In this article, we will explore low-volume CNC machining in detail, discussing its benefits and ways to maximize your budget when designing for this type of machining. Keep reading for valuable insights!
Low-volume CNC machining merges the advantages of computer numerical control with CNC principles to produce a limited number of pieces. Not all businesses require large product batches; some need smaller quantities.
Moreover, low-volume machined products are cost-effective and do not necessitate expensive tooling. This approach is ideal for progressing an idea from the conceptual stage through prototyping, serving as a transitional phase to full-scale production.
Businesses utilize low-volume CNC for various beneficial reasons, ranging from cost efficiency to capital protection. Let’s explore the advantages of low-volume CNC in more detail.
Low-volume CNC machining offers greater design flexibility compared to injection molding or die casting. It becomes easier to identify manufacturing mistakes and make necessary adjustments at minimal cost. Companies that produce low-volume products can incorporate customer feedback to enhance their offerings for optimal client satisfaction.
As technology, trends, and consumer preferences evolve rapidly, competition among businesses in the same industry intensifies. Low-volume production ensures that high-quality products and parts reach the market quickly, keeping businesses competitive.
Low-volume CNC machining enhances cash flow between customers and businesses by reducing time to market. This increased turnover rate allows products to enter the market quickly, driving sales and enabling businesses to generate revenue and profit more rapidly.
Low-volume CNC machining acts as a bridge between prototyping and full-scale production. Prototyping focuses on creating custom goods, while full-scale production occurs when there is high demand.
Low-volume CNC machining produces high-quality parts with tight tolerances and excellent surface finishes. This precision is due to the capabilities of CNC machines, which can manufacture parts to exact specifications.
Here are some design tips to help you minimize the budget and time spent on low-volume CNC machined parts.
When designing low-volume CNC machined parts, aim to keep the designs simple and uniform. Complex designs often require more expensive CNC systems, manual repositioning, and rotation. Therefore, it can be beneficial to break down a complicated piece into smaller parts for later assembly.
Here are some key considerations:
1.1 Go with Standard Threads
Using standard threads, similar to standard drill sizes, can save time and money during low-volume production. This approach involves utilizing an existing thread class rather than creating a unique thread for the machining process.
1.2 Avoid Tight Tolerances
Tight tolerances can increase setup time, as well as inspection and machining time, often necessitating specialized production techniques or secondary operations. It's best to ensure that tolerances are only as tight as necessary to meet the structural and functional requirements of the design.
1.3 Use Standard Sizes When Designing Holes
As the depth of a hole increases, the metal chip evacuation process becomes more challenging and costly. Aim to keep the hole depth to five or six times the drill diameter. Additionally, design your holes using common drill sizes to avoid the need for unique tools, which can raise costs and extend manufacturing time.
Selecting the right materials is crucial for both long and short production runs, as using the wrong materials can lead to skyrocketing project costs. Machinability is another important factor to consider, as even if different materials are available, one may be significantly more expensive than another.
In other words, when choosing a CNC machine shop, opt for a less expensive and/or more common material if the specialized properties of costly or unique materials are not required.
When designing low-volume CNC machined parts, it's best to avoid elaborate finishing and text. Although machined text can enhance visual appeal and operational functionality, the process increases production time and costs for each character due to the techniques required to track them accurately.
If your low-volume machined parts require a logo or lettering, consider using a surface finishing technique, as this approach can save both time and money. For instance, adding text to your product is quicker through methods like direct engraving using laser marking, painting, or silk screening.
Designing for manufacturing involves creating parts that are easy to machine. It’s essential to consider the capabilities of the machining equipment when planning for low-volume machining. Ensure that the parts can be produced using the available tools; for instance, if you have a 3-axis CNC machine, avoid designing products that require a 5-axis CNC machining process.
Reducing waste is vital for lowering CNC machining costs and addressing environmental concerns. When designing for machining or low-volume injection molding, focus on material usage and create pieces that generate minimal waste. To further reduce material waste, consider requesting the use of recycled materials.
Low-volume manufacturing involves producing a small quantity of a product or part. The information provided above highlights essential aspects of this CNC machining production practice. Additionally, we explored ways to maximize your budget when designing for low-volume CNC machining to assist you in making informed decisions.
What are low-volume manufacturing methods?
Before moving to high-scale production or when demand is low, businesses often test their products in the market using low-volume techniques. Examples of low-volume options include 3D printing, CNC machining, and injection molding. Each of these methods has its benefits and drawbacks, making them suitable for specific applications.
Is CNC good for mass production?
CNC machining is widely utilized across various industries because it produces goods with high precision and accuracy, thereby reducing the likelihood of human error. This method is essential in sectors where mass output, cost-effectiveness, and accuracy are critical.
Is additive manufacturing a better alternative to low-volume production?
Additive manufacturing is generally more suitable for projects that require quick delivery of final parts or prototypes and have relaxed tolerance requirements. In contrast, CNC machining is better suited for projects that demand tight tolerances or a low-volume approach with part counts in the upper double digits or low thousands.
