How to Choose the Best CNC for Rapid Prototyping - DATRON

Find the Best CNC for Rapid Prototyping

The road to insourcing your prototyping can be a long, yet knowledge-filled journey. Hopefully our previous discussions on rapid prototyping in-house have educated and inspired you to take the reins on manufacturing your own prototypes. Now it’s time to think about how to find the best CNC for rapid prototyping.

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Once you’ve decided to take the plunge, where do you begin? After you’ve tackled the question of whether to use additive or subtractive methods, it’s time to start picking the machine that’s right for you. If you decided that a CNC machine is part of your solution, you’ve come to the right place! Let’s take a deep dive into the CNC universe and help make sense of it all.

How Do I Choose the Right CNC Machine?

Before looking outward for the right CNC machine, it’s best to look inward at your product line up. Understanding the requirements of your own products will help define what machine is the best fit for your prototype lab. Define what materials you’ll be working with, what dimensional tolerances you need to hold, and what sort of geometric features you need to create.

Besides the mere functionality of the machine, it’s also critically important to examine what it’s like with day-to-day use.

• Is the machine easy to use and maintain?
• Is programming the part inherently difficult?
• Will there be support available when you need it?
• What will it cost to power and tool up the machine?

What Are My CNC Options?

There is an extremely wide variety of CNC machines available for your consideration – it can be a daunting task when presented with all the options. Not to worry, though – this is where you fall back on the basic questions: tolerance, shapes, and materials. Keeping these in mind will help make choosing the right machine a lot easier.

Let’s break it down:

CNC Plasma Cutter

Commonly used for steel sheet metal, a CNC plasma cutter is an affordable, fast, and efficient way to burn through a variety of conductive materials. While there are some multi-axis plasma cutters on the market, they are commonly 2 axis machines. The drawbacks of CNC plasma cutters in rapid prototyping are its inherent limitations in 2 axis form, relatively poor cut quality, and hefty workplace safety requirements. Unless you’re enhancing a fabrication/welding process in your prototyping facility, a CNC plasma cutter is probably not your best bet.

CNC Laser Cutter

A step up from plasma, CNC laser cutters have grown in popularity in recent years and it’s easy to see why. Lasers can cut a wider variety of materials besides metal, including plastics, wood, and fabrics, all with relative ease.

As well, they can quickly create detailed (yet shallow) engravings. On top of that, they work very quickly and are typically cleaner, self-contained units.

However, there are some issues with using laser that need to be considered. Lasers use immense amounts of heat to break through the material, which can harden edges, making them more brittle. Also, despite being quite accurate, laser cuts will leave a slight taper on edges, which can hinder dimensional accuracy needs.

Since laser cutters are typically 2 axis machines, they are limited on what features they can create. While they can ablate away layers to create greater feature depth, they do so very inefficiently with regard to energy consumption and time, at the cost of potentially warping the part from excessive heat. This narrows the effective use of CNC laser cutters considerably, especially for rapid prototyping.

CNC Waterjet Cutter

Waterjet cutting is an effective way to cut thin or thick material of nearly any type. Using high pressure water along with an abrasive media, called garnet, water jet is a great substitute for laser or plasma cutting. It also creates less waste by using a closed-loop water circulation system. The downside to all of this comes with the cost of up-keep; maintaining filters, pumps, and nozzles can be a significant task. When comparing to CNC laser cutting, CNC waterjet is fairly inaccurate, typically only capable of holding a 0.005” tolerance, however, the cut quality may be nicer.

CNC Router

While routers are a type of CNC milling machine, they are usually categorized completely separately. This is primarily due to their design: CNC routers have a gantry frame construction, with a large bridge spanning over the machine table. This inherently allows for a large work envelope without sacrificing floor space. CNC routers are typically tasked with milling large panels of wood, plastic, or softer metals, like aluminum.

They also have the ability to mill with all 3 axis which allows for more complex features than the previous three machines, such as counterbores, chamfers, and pockets.

Keep in mind, if you’re new to the concept of machining, learning to use a CNC router will have a steeper learning curve than the other items mentioned. There’s a lot to learn about machine control, cutting strategies, milling tools, etc… Also, routers are typically disregarded by most machinists because of their lack of rigidity and accuracy, thus making them a distinct upgrade from CNC waterjet, but not quite as precise as a CNC mill.

CNC Lathe

Lathes are an essential part of the history of machining. Being called “mother of machine tools” dating back as far as the 13th century, lathes have since evolved to adopt CNC technology, and are still integral to manufacturing today.

Unlike the previous equipment, lathes are built to machine round parts exclusively. Where a CNC Router has stationary material and a spinning tool, lathes have spinning material and stationary tools.

This is highly ideal for cylindrical parts, like bolts, tubes, and washers, especially when very tight tolerances are necessary (less than 0.001”).

While a lathe is extremely capable and useful, it may not be your first choice when building your prototype lab. Unless your products are ideal lathe parts, like those mentioned above, a lathe is a bit too focused to be a well-rounded rapid prototyping machine.

CNC Milling

A CNC mill is one of the most common tools to see in a prototyping lab – and for good reason. Mills are robust, and flexible machines, that are suitable for a wider variety of parts and materials then the other machines mentioned. Allowing for complex features, like threaded holes, deep pockets, and 3D surfaces.

Typical CNC mills use a “C frame” design – a spindle that moves up and down, and a table that moves left/right and back/forth. With an extremely heavy build and large footprint, they are quite reputable for their precision, often holding tolerances of 0.001” or less – a quality that most of the aforementioned machines are not well known for.

Roadblocks to CNC Milling

The biggest hurdle to overcome with CNC mills isn’t “What can it make?”, but “Who can make it?”. There are layers of complexity to using a CNC milling machine – first, the operation of the control is an art unto itself. Typical CNC controls are extremely capable, but quite intimidating. With a vast array of buttons, switches and knobs, alongside a deep structure of software functions and menus, most controls will likely have you holding onto a user’s manual for dear life.

Then there’s the setup of the machine, which is a critical task for creating quality parts. This involves alignment of workholding to the machine’s axis, loading and measuring of tools, and setting correct program parameters. When done improperly, in the best case; you have successfully made scrap parts and need to start all over again. In the worst case; you have broken tools, workholding and machine – creating a serious dilemma and effectively making “rapid prototyping” an oxymoron.

Last, but not least, there’s programming. Aside from operating the machine, there’s a bit of skill required to programming a part in a CAD/CAM software. This, luckily, is getting easier all the time, with excellent options like Autodesk Fusion 360 which can simplify the process for new users. However, the hardest part is often not with applying toolpaths, but with setting the right parameters. Choosing the right cutting tool, feed rate, spindle speed, depth and width of cut, can be an uphill battle – and it changes by what material you use, and what features you make.

Striking the Right Balance

There are a lot of options, but the answer seems straight-forward; the most well-rounded rapid prototyping solution is CNC milling. However, the barrier to entry is real. Having an experienced CNC machinist on staff becomes a prerequisite, and as you may have heard, finding a qualified CNC operator is not getting any easier.

The issue is clear – there’s a skills gap in manufacturing that needs to be addressed, but even if drastic measures were introduced now, it will be many years before skilled labor starts in the workforce.

DATRON has been listening to this concern over the past decade, and they know just how to solve it.

While computer power and capability has made significant strides over the past decade, the typical CNC control has not. It’s still as cumbersome to use as ever, making alternative manufacturing technologies like 3D printing even more desirable. If convolution is the problem, then the solution is simple, or rather, the solution is to simplify.

CNC Milling for the Modern Era

Simplification is the goal with DATRON’s next control. Next is designed from the ground-up to focus on ease-of-use, without sacrificing industrial capability. With a familiar tile-based design, not unlike a smart , next is uncluttered and easy to understand immediately. Besides a pleasant visual design, next incorporates clever software engineering to make setup easy. The CAM Wizard walks you through loading the program, setting the tools, even probing the workpiece, as painlessly as possible.

Upgrading the control is just one way DATRON makes CNC milling more approachable. Setting up workholding has been optimized by utilizing a conical grid system, for quick and repeatable fixturing without any need to manually align. As well, accessories like vacuum tables make machining plate material quick and painless.

What is prototyping, and how is it effective in CNC machining parts? More professionally, if we want to build any product, we make its prototype before going into mass production. These products can be anything from metal parts, airplanes, cars, toys, or electronic devices.

Let’s discuss it in simpler words. A prototype is a basic product version that assists designers or technicians in improving their design. If they find any issue, they can fix it before going into large-batch manufacturing. So in this context, rapid prototyping CNC also plays its part in prototype machined parts. Rapid CNC prototyping delivers the following advantages:

1. Quicker Turnaround time
2. Higher Fidelity
3. High Precision

For a basic understanding for beginners, prototyping is the early stage of rough model production. It helps in testing the viability of a design or process. Prototype is a beginner step between your initial idea and the final product.

How can CNC machining help in prototyping?

As you can read a brief introduction on CNC machining in the link below, we shall provide a concise concept. CNC machining is a method to make high-precision parts. We use computer-controlled machines to remove material from a solid block in this type of machining method. Hence, these machines produce a precise prototype of your design.

The goal of CNC machined prototypes is to get your idea out of your head and into a physical form to:

Visualize the design:

How would it look like in the final production?

Test functionality:

Ensure different parts work together as planned in the design process.

Identify flaws:

Discover weaker areas before investing in mass production.

Read More:

CNC Machining Basics

What Is CNC Machining：From Basics To Advance

Goto Prototype Finder to know more.

What is CNC Prototype Machining?

If you have seen a professional sculptor, what if he uses a CNC machine instead of traditional tools?

Here are three main stages of CNC machines that execute any prototype:

1: Part Design

2: CNC Machine Tools Setting

3: CNC part Manufacturing

So, let’s explain each briefly.

Part Design

Prototype CNC machining starts with the ideas for a part. Engineers and designers use CAD software to make a comprehensive digital model. They make sure about the minute details such as dimensions and tolerances. They also incorporate materials and turnaround time. This digital model plays a crucial role in determining the final manufacturing.

CNC Machine Tool Settings

As soon as we finalize the design, we will send it for CNC machining. This step involves using CAM software that effectively translates the CAD model into a CNC program. This software helps in generating toolpaths and cutting the following:

1. The part’s geometry
2. Tooling parameters
3. Machining requirements.

At this stage, a professional CNC machining center will focus on choosing the right cutting tools, materials, and fixture methods. Subsequently, they also control machining parameters, for instance, cutting speeds and feed.

CNC Part Manufacturing

The next step is to load the CNC program into the machine’s control unit. Later, the operator sets up the workpiece on the CNC machine. The machine can be 3, 4, or 5-axis. Following the programmed toolpaths automatically, the CNC machine uses cutting tools to shape the workpiece according to the design. The machine adjusts cutting parameters automatically for greater precision during the entire process.

Read More:

Top 10 China CNC Machining Companies

Top 5-Axis CNC Machining Companies

Why Choose CNC Machining for Prototyping?

CNC machining is one of the prominent choices for making prototypes due to numerous critical advantages:

Greater Precision

CNC machining is quite popular due to its tight tolerance ability. Since it works on software, the cutting-edge technology of a CNC machine can effectively control the dimensions of prototype machined parts. This high level of accuracy makes the CNC machining method a prominent choice. Because making parts with complex geometry is highly convenient.

Rapid Prototyping

Time is everything in product development. Therefore, CNC machining is the best choice to accelerate part manufacturing. CNC machining is relatively faster than traditional machining methods. Thanks to its automated computer-controlled process, CNC is much quicker than manual machining. Rapid prototyping CNC is crucial when multiple prototype iterations are required for further design improvements.

Read More:

CNC Machining vs Manual Machining

Better Choice of Materials

CNC machining has the potential to machine several important materials. This includes metals like:

• Aluminum and steel: Aluminum is a popular choice for lightweight prototypes due to its excellent machinability and versatility. Collaborating with experts in CNC machining aluminum ensures precision and efficiency in creating high-quality components.
• Plastics: Plastics are frequently used for prototypes and low-weight applications. Leveraging specialized CNC machining for plastics ensures that even delicate materials are processed accurately without compromising their integrity.
• Titanium: Titanium stands out for its strength and corrosion resistance, making it ideal for advanced prototyping. Working with specialists in CNC machining titanium ensures that this challenging material is handled with the precision it demands.

Choosing the right material is important for guaranteed results at the prototyping stage.

Common CNC Prototyping Options

CNC machining comes with a range of different manufacturing processes which is suitable for making CNC-machined prototypes. Generally, there are three procedures we follow in CNC machining. Let’s discuss each:

Turning

CNC machining centers use a lathe to shape prototypes like metal and plastic in this method. Turning tools keep rotating the workpiece by removing the extra material following CNC prototypes. It is commonly used in manufacturing shafts, pins, and bushings. For businesses needing reliable solutions, partnering with a trusted turned parts manufacturer can ensure precise results for all turning requirements.

Milling

In this method, the machinist places the workpiece on the table, where the tools do the rest of the job. These tools can move in multiple directions, following the computer’s commands. This process helps them in making the desired shape. The flexibility of the tools makes milling a prominent choice for making CNC machined prototypes. If you’re looking for a dependable CNC milling service China, Yijin Hardware offers advanced milling solutions tailored to your specific needs.

Multi-Axis Machining

In multi-axis machining, the machinists use more than three axes. Multi axes allow machining centers to make prototypes with higher complex designs. This method also reduces the material waste. In more simple words this technique is like a sculptor with multiple hands working on different directions of the part.

Applications of CNC Prototype Machining

The unique capabilities of CNC machines make machining methods appealing. Therefore, in CNC rapid prototyping, hobbyists prefer to work with these methods because they can execute complex shapes flawlessly.  Here are a few cnc application examples:

More Functional Prototypes

Incorporating CNC machines is about more than just prototyping. The sole purpose is to demonstrate the effectiveness of the prototype machined parts. For example, a prototype product can give us functional and design aspects. Hence, we can detect the flaws quickly which ultimately helps us to improve our design.

Aerospace

With the new developments in the aerospace industry, everyone is looking for more reliable and lightweight parts. With CNC machines, we can effectively use titanium and aluminum alloys to make prototypes.

Automotive

CNC machining is playing a decisive role in manufacturing automotive industry prototype parts. Since car engines demand higher accuracy; CNC machining can meet the tight tolerances effectively.

Medical Devices

Precision is everything in the medical industry. Therefore, CNC machining is here to make accurate prototypes for medical devices. Here again, materials like titanium and stainless steel enhance the productivity of the machining process.

Benefits of Prototyping with CNC Machining

Design Verification and Iteration

CNC-machined prototypes offer a solid space for hobbyists to make a perfect part before mass production.  Prototyping a machined part allows you to check the design and make further improvements. Hence, you can make quick modifications.

Lower Investment

Since CNC machining is expensive, we cannot test the product in mass manufacturing. It will lead to greater upfront costs which can be discouraging for the buyer too. CNC prototyping provides both cost-effective and quick solutions to overcome these challenges.

Vast Material Compatibility

Making prototypes in CNC machining is easy due to an extensive range of material selection. This characteristic gives machining a significant advantage over other prototyping methods.

For example, unlike 3D printing, CNC can make prototypes with any plastic material. This quality allows designers to assess the prototype performance accurately. Moreover, it reduces the initial investment, too. The other factor is the evaluation of material behavior. Machinists can easily check:

• Tolerance

• Material machining capacity

• Possible surface finishing.

Limitations of CNC Prototyping

While CNC machining offers an impressive array of benefits for prototyping, it’s essential to acknowledge its limitations:

Material Waste

CNC machining is a subtractive manufacturing process. It means due to the limitations of the axis, there are higher chances of material waste. But modern CNC 5axis machines have solved this issue. Since it can work in multiple directions, the material waste is pretty low.

Cost per Unit

Although CNC machining produces accurate prototypes, its cost for precision is relatively high. For instance, single batches of prototypes can be much more expensive as compared to well-designed part mass production. The reason is the initial setting up cost of machines.

Key Considerations for CNC Prototyping

No doubt, CNC machining provides excellent capabilities but there are some considerations also. A machinist should undertake them before executing any prototype project.

Design Complexity

CNC machines are popular due to their efficiency in making perfect prototype parts for complex designs. However, if there are prototypes with complex designs, it can be challenging for CNC machines. Therefore, it is essential to consult with a professional CNC machining company.

 Material Selection

Selecting the appropriate material is crucial to making a CNC machined prototype. CNC machining can handle a wide range of materials. For a beginner, some aspects need to be considered such as:

• Strength
• Weight
• Heat resistance

The same prototype cannot be used for all fields. We need to select materials according to industry requirements.

CNC Machining vs. 3D Printing

As we have discussed earlier CNC machining is a manufacturing process that can work swiftly on various materials with greater precision. However, it can be more expensive, especially for making prototypes. On the other side, 3D printing makes parts by adding layers gradually. You can say similar to a high-tech glue gun. Simultaneously, 3D printing is not only faster but also cheaper. It can effectively work on simple designs. However, CNC machining is a better choice for prototypes requiring metal strength.

CNC Machined Prototypes vs. Injection Molding Prototypes

Choosing the proper prototyping method is crucial for any end-product performance. Comparing both methods will allow you to assess their functions, strengths, and weaknesses. For instance, skilled technicians can evaluate the material limitations of both methods during testing. Ultimately, it will help for further product refinement.

To learn more about their differences, feel free to read our detailed guide: CNC Machining vs. Injection Molding

For more rapid prototype machining(ja,es,it)information, please contact us. We will provide professional answers.

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