How to cut CNC manufacturing costs? ⚙️
Reducing CNC manufacturing costs is essential for maintaining competitive pricing and optimizing production efficiency. Here are practical steps to lower costs without sacrificing quality:
1. Select Cost-Effective Materials and Standard Stock Sizes
Choose affordable materials: Base material costs can vary significantly. Opt for materials that are easier to machine, as they require less time and reduce wear on tools. For example, certain aluminium alloys are cheaper and easier to machine than harder metals.
Optimize stock size: Use material stock sizes that are close to the final part dimensions. This reduces material waste, minimizes machining time, and cuts down on disposal costs.
2. Simplify Part Design to Minimize Machining Time
Reduce complexity: Complex geometries require longer machining time and may need multiple setups, increasing labour and time costs. Simplifying your design can make the process faster and more efficient.
Eliminate unnecessary features: Minimize intricate details that don’t contribute significantly to the part’s function. For example, reducing the number of small radii and fillets can save time and tool wear.
3. Optimize Wall Thickness
Thicker walls are easier and cheaper to machine: Thin walls increase machining time as they require smaller cuts to avoid breakage. Generally, use a minimum wall thickness of 1.5mm for plastic and 0.8mm for metal to maintain part integrity and lower costs.
Avoid extremely thin features: Thin walls are prone to vibration and deformation, which can increase machine setup and cutting time.
4. Limit Thread Length
Use shorter threads where possible: Avoid over-specifying thread lengths. Threads longer than 1.5 times the diameter of the hole do not typically add strength and increase machining time.
Blind holes: For threads in blind holes, increase the unthreaded length at the bottom of the hole to reduce machining time and tool wear.
5. Use Standard Hole Sizes
Choose standard drill sizes: Using standard-sized drills reduces machining time and avoids custom tooling costs. Non-standard hole sizes require additional machine setups, which increase labour and time.
Limit hole depth: Holes should ideally be no more than four times their diameter. Deeper holes are challenging to machine accurately and increase wear on tools.
6. Avoid Small Features with High Aspect Ratios
Reduce high aspect ratio features: Features with high width-to-height ratios (narrow and tall) are challenging to machine due to vibration, which impacts tool life and machining precision.
Add support or brace ribs: If tall, thin features are necessary, reinforce them with bracing or connect them to more robust walls to minimize vibration and improve rigidity.
7. Use Automation Where Possible
Automate tool changes and production processes: By designing parts that can be produced in a single setup, you reduce the need for multiple tool changes and manual handling, which lowers labour costs and machine downtime.
Standardized designs: Standardized components reduce custom machining steps, allowing for more straightforward and automated machining processes.
8. Optimize Tool Selection and Machining Parameters
Choose durable tooling: Carbide or coated tools are ideal for extended tool life, especially when working with harder materials. Though they may cost more upfront, they last longer and reduce downtime.
Adjust speeds and feeds: Fine-tuning spindle speed, feed rate, and depth of cut based on the material and tool helps reduce tool wear and achieve efficient machining without excessive energy costs.
Stoney CNC’s Support for Cost-Effective CNC Machining
At Stoney CNC, we offer guidance on design and manufacturing to help you achieve cost-effective solutions. From our range of high-performance CNC systems to expert consultation services, we support efficient production tailored to your needs. Our team can assist you with design adjustments to streamline your process and minimize costs, making your CNC machining as efficient and affordable as possible.
By implementing these strategies, manufacturers can effectively lower CNC machining costs while ensuring high-quality output.
