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CNC Machining

Understanding the Benefits of 5-Axis CNC Machining

In modern manufacturing, 5-Axis CNC machining has emerged as a transformative technology, unlocking fresh opportunities for precise engineering and surpassing traditional boundaries. This advanced manufacturing process offers unparalleled capabilities, enabling the creation of intricate components that were once considered impossible or too expensive to produce. 

Harness the potential of 5-Axis CNC machining for your next manufacturing endeavor. Partner with Elemet Manufacturing and unlock a new realm of possibilities. Our expert team and state-of-the-art technology are poised to bring your innovative designs to life with precision and efficiency. Contact us today to embark on a journey of limitless manufacturing potential.

 

Exploring 5-Axis CNC Machining

Imagine a world where complex shapes and intricate geometries can be crafted with precision and efficiency, all in a single setup. That world is now a reality thanks to 5-Axis CNC machining. 

This cutting-edge technology allows cutting tools to move simultaneously across five axes, enabling the production of intricate structures and features that would be difficult or impossible to achieve with traditional machining processes.

5-Axis CNC machining is a special process that provides advantages over other traditional machining processes. What makes it so special? 

To truly appreciate the power and versatility of 5-axis CNC machining, it’s essential to understand its underlying principles and the various types of machines available. With different configurations designed to suit specific manufacturing needs, 5-Axis CNC machines are revolutionizing the way we produce parts and components.

 

Defining 5-Axis CNC Machining

Benefits of 5-Axis CNC Machining

At its core, 5-Axis CNC machining involves the simultaneous movement of cutting tools across five different axes, allowing for the fabrication of intricate and accurate components from virtually any direction. The process begins with the creation of a 3D CAD model of the desired part. This model is then imported into CAM software, which generates a computer program, or G-code, containing instructions for the CNC machine. 

These instructions control the movement of cutting tools and/or the workpiece along linear axes (X, Y, and Z), as well as the rotational axes (A and B), allowing the machine to create the desired part with precision and efficiency.

The benefits of 5-Axis CNC machining are numerous, including increased accuracy and reliability, the ability to create complex geometries, improved surface finish quality, and cost and time efficiency. One key distinction between 5-Axis CNC machining and its 3+2-Axis counterpart is the continuous synchronized movement of the machine and workpiece along all five axes. 

This facilitates the crafting of intricate geometries, rather than just executing a 3-axis program with the machine components locked at an angle determined by the two rotary axes, as in the case of 3+2-Axis machining. This subtle difference results in a more precise and versatile machining process, perfect for tackling even the most complex of geometries.

 

Types of 5-Axis CNC Machines

As diverse as the parts they create, 5-Axis CNC machines come in various configurations, each designed to suit specific manufacturing requirements. The primary distinction between these machines lies in the arrangement of their rotary axes. 

For example, the Head/Head configuration features two rotational axes housed in the head, with a 5-axis apex that moves through a fixed worktable to keep the workpiece stationary. On the other hand, a Table/Table 5-Axis CNC machine has rotary axes on the table, making it ideal for machining undercuts but less suitable for large or heavy components.

Another popular configuration is the Head/Table setup, which comprises one rotational axis in the machine spindle head and the other in the rotary table. As the tool rotates, trunnion-style 5-axis CNC machines, for instance, feature an A-axis rotating around the X-axis and a C-axis rotating about the Z-axis, both located within the table, while the head remains stationary.

Understanding the unique capabilities of each type of 5-Axis CNC machine is crucial for selecting the most suitable machine for your manufacturing needs.

 

Key Benefits of 5-Axis CNC Machining

Teamwork professional engineer working heavy industry in factory, engineering wear uniform industrial machine maintenance working in factory. professional worker control manufacturing.

5-Axis CNC machining offers numerous advantages that make it a preferred choice for industries requiring high-precision components with complex geometries. Some key benefits include enhanced precision and repeatability, the ability to create intricate shapes and contours in a single setup, improved surface finish quality, and significant time and cost savings.

Let’s explore each of these benefits further and their impact on manufacturing capabilities.

1. Enhanced Precision and Repeatability

One of the most significant advantages of 5-axis CNC machining is its superior precision and repeatability. With minimal setups required and the elimination of manual repositioning, 5-Axis machines can consistently produce parts with tight tolerances and intricate details. This level of accuracy is especially valuable in industries such as aerospace and medicine, where even the slightest deviation from specifications can lead to catastrophic consequences.

Moreover, 5-Axis CNC machining facilitates the use of shorter cutting tools, which, coupled with optimal tool-workpiece engagement, reduces the risk of tool deflection and vibration. The result is a more stable cutting process, leading to greater accuracy and repeatability in the finished part. This level of precision simply cannot be achieved with traditional 3-axis CNC machining, making 5-axis technology a clear choice for manufacturers seeking to produce high-quality components consistently.

2. Complex Geometry Capabilities

5-Axis CNC machining truly shines when it comes to creating complex shapes and angles. Unlike traditional machining processes, which require multiple setups and reorientations to achieve desired geometries, 5-Axis CNC machining can produce intricate parts in a single operation. This capability is particularly useful for industries that require highly specialized components, such as aerospace, medical, and energy production.

The ability to machine complex shapes in a single setup not only saves time but also reduces the likelihood of errors caused by manual repositioning. Additionally, 5-axis CNC machining enables the creation of contoured edges and compound shapes that would be challenging or not feasible to accomplish with traditional machining techniques. As a result, manufacturers can produce more intricate parts and designs, unleashing new possibilities in product design and innovation.

3. Improved Surface Finish Quality

Surface finish quality is a critical factor in the performance and longevity of a component, and 5-Axis CNC machining excels in this area. By utilizing shorter cutting tools and improving spindle utilization for angled surfaces, 5-Axis machines can deliver smoother surface finishes with fewer tool marks. This translates to a higher-quality finished product that meets or exceeds industry standards.

Additionally, 5-Axis CNC machining allows for optimal tool orientation and constant tool-to-workpiece contact, resulting in more even surface finishes when machining angled surfaces. This is especially important in industries such as aerospace and medicine, where surface quality plays a crucial role in the functionality and lifespan of components.

With the ability to achieve superior surface finishes, 5-Axis CNC machining is a valuable asset for manufacturers looking to deliver high-quality products consistently.

4. Time and Cost Savings

Cost efficiency is a top priority for manufacturers, and 5-Axis CNC machining delivers significant savings in both time and money. By reducing the need for multiple setups and manual repositioning, 5-Axis machines can complete complex jobs more quickly and accurately than traditional machining processes. This not only speeds up production time but also minimizes the risk of errors that can lead to costly rework or scrap.

Furthermore, 5-Axis CNC machining can be automated, reducing labor requirements and further contributing to cost savings. With the ability to produce more complex parts in less time and with fewer resources, 5-Axis CNC machining is an attractive option for manufacturers looking to improve their bottom line while maintaining high-quality standards.

 

Design and Create Without Limitations

5-axis CNC machining holds tremendous potential for manufacturers across various industries. This revolutionary technology redefines the boundaries of precision and complexity in component fabrication, making it an integral part of modern manufacturing practices.

With notable efficiencies in time and cost, 5-Axis CNC machining is a valuable asset for manufacturers targeting operational optimization. The minimized setups and potential for automation highlight its role as a key driver of manufacturing excellence.

As technology continues to evolve, 5-Axis CNC machining is poised to play an even larger role in precision manufacturing. By unlocking a new realm of possibilities, it continues to redefine what’s feasible in precision manufacturing, enabling us to dream and create without limitations. For anyone seeking to leverage the power of advanced manufacturing, embracing 5-Axis CNC machining represents a step into the future.

At Elemet Manufacturing, we’re excited to guide you on this journey, bringing your most innovative designs to life with unmatched precision and efficiency. Let’s explore the possibilities together – contact us today to get started.

Categories
CNC Machining

What Industries Use CNC Machining?

Advanced CNC machining can play a valuable role in creating precise parts and products that fill high-level needs in a wide range of industries, such as the aerospace, medical, electronics, and defense industries. 

From building airplanes that are as safe as possible to creating prototypes for possible new medical devices, industrial CNC machines significantly reduce the possibility of human error and increase consistency by making sure that every part is manufactured exactly according to preset standards.

Here are four industries that benefit the most from the quality and consistency of CNC machined parts. 

Aerospace

CNC machines manufacture an array of intricate components, ensuring safety and functionality across all aerospace equipment, from airplanes and helicopters to satellites and drones. Extreme conditions such as high air pressure, intense speeds, and shifting air currents require each piece to withstand these forces without premature wear or safety compromises.

These versatile machines don’t just create the parts. They also manufacture components for the machines that service and maintain various aerospace equipment, keeping everything in top-notch condition.

Three African mechanics repairing a plane engine in the hangar

CNC machines work in a broad spectrum within the aerospace industry, manufacturing a diverse range of parts like:

  • Landing gear for both aircraft and space rovers
  • Antennae for communication in aircraft and satellites
  • Electrical connectors used in various aerospace systems
  • Airfoils for aircraft, helicopters, and drones
  • Rocket engine components
  • Spacecraft structural parts
  • Satellite chassis
  • Propellers for aircraft and drones
  • Turbine blades for jet engines
  • Radiofrequency suppression materials for various communication devices
  • Components for robotic equipment used in space exploration

The aerospace industry requires exceptional precision and standardization, and this is where CNC machines demonstrate their indispensable value. Performing a variety of subtractive manufacturing operations, including drilling, shaping, and milling, CNC machines follow meticulously programmed instructions to ensure the production of identical, high-quality components. 

This level of automation affords a degree of accuracy and reliability that surpasses what is achievable with traditional, more manual control manufacturing methods. In essence, CNC machines play a vital role in minimizing the potential for human errors, thereby establishing themselves as invaluable assets in maintaining the high standards of the aerospace industry.

Transportation 

While the specific requirements for aerospace parts are unique, many components used in other forms of transportation – such as trains, buses, automobiles, and ships – bear similarities in their purpose and construction. Every vehicle type is subject to its own set of hazards, necessitating robust parts that ensure their safe operation under these varying conditions.

For instance, the high-speed operation of bullet trains demands structural components that can withstand the intense forces induced at such velocities. Similarly, the hulls and superstructures of ships must be meticulously constructed to endure harsh marine environments and prevent water ingress. It’s imperative that there are no gaps or flaws in the cutting of these parts that could compromise the vessel’s structural integrity.

The tighter tolerances provided by CNC machines in producing these parts are invaluable, offering far greater consistency and fit than manual methods. Therefore, CNC machining is not just a preference but a necessity for ensuring the vehicles can withstand their intended use.

Medical 

Modern knee and hip prosthesis made by cad engineer and manufactured by 3d printing

The importance of functioning medical equipment cannot be overstated for patient safety and healthcare outcomes. This is where precision and consistency come in, and CNC machining shines in these areas. It’s vital in a field where many parts are used only once, meaning facilities constantly need a large number of identical parts. These parts need to be a perfect match in size and fit each time, which CNC machining can deliver.

CNC machining finds extensive use in the healthcare sector. It’s used in:

  • MRI Machine Components
  • Diagnostic Equipment
  • Research Equipment
  • Implants
  • Orthotic Devices
  • Surgical Instruments
  • Dental Instruments
  • Bone Screws
  • Spinal Implants
  • Prosthetics

Detailed accuracy is of paramount importance in medical settings where even the slightest discrepancy can impact patient outcomes. Through CNC machining, the industry can ensure the production of high-quality, reliable, and safe medical equipment, thus driving advancements in patient care.

Oil and Gas

The oil and gas industry serves as a lifeline to our modern lifestyle, but it also presents significant safety challenges. Every component of this complex infrastructure, from the drilling rigs to the storage facilities and transportation vehicles, demands high-precision parts to ensure the safe handling and transport of these vital resources.

The precision in part manufacturing, achieved through CNC machining, is paramount to prevent leakages that could contaminate drinking water, compromise air quality, or cause environmental and human health hazards. Furthermore, inaccurately machined components may malfunction, resulting in the loss of valuable resources and potentially damaging the costly infrastructure.

CNC machines play an integral role in the oil and gas industry by producing a variety of critical components, including:

  • Pistons
  • Valves
  • Rods
  • Cylinders
  • Pins

Through exactitude and uniformity offered by CNC machining, the industry can optimize resource extraction, processing, and transportation, mitigating environmental risks and enhancing operational efficiency.

Final Thoughts

At Elemet Manufacturing, we harness the power of state-of-the-art CNC machining to produce a wide array of specialized products. These cater to the unique needs of several forward-thinking industries. Choosing parts created through our CNC process brings numerous benefits over traditional manual methods, such as increased precision, improved consistency, and a significant reduction in human error.

These factors contribute to enhancing the safety and effectiveness of products across a range of industries. We’re ready to help you discover how our expertise in CNC machining can provide meaningful support to your business. 

Contact us today for more information about how our advanced CNC machining can benefit your business or to request an estimate!

Categories
CNC Machining Metal Fabrication Waterjet Cutting Welding

Unlocking the Potential: 6 Benefits of End-to-End Product Manufacturing

In today’s rapidly evolving business landscape, efficient and streamlined product manufacturing processes are crucial for companies seeking to bring their products to market quickly and cost-effectively. One approach that has gained significant traction is end-to-end manufacturing production. 

In this article, we will explore the concept of end-to-end manufacturing production and highlight its numerous benefits to businesses. Elemet Manufacturing, a leading provider in this field, exemplifies the advantages of a comprehensive manufacturing management solution. If you’re looking to optimize your production process, Elemet Manufacturing has the expertise and resources to help. Contact Elemet Manufacturing today for more information.

 

Understanding End-to-End Product Manufacturing

Isometric industrial production line packaging new goods. Conveyor with gears, spare parts passing through metal detector. Man puts parcels in cardboard boxes.

End-to-end product manufacturing refers to a holistic approach where a single manufacturer takes responsibility for the entire lifecycle of a product, starting from the initial design concept to the delivery of the final finished goods. This approach eliminates the need for businesses to engage multiple companies for different manufacturing stages, simplifying the process and ensuring a more efficient and seamless production journey.

Overview of the Various Stages Involved

  • Product Design

The first stage in end-to-end product manufacturing is product design. This involves translating ideas, concepts, and specifications into a tangible design blueprint. The design team works closely with the client to understand their requirements and develop a design that meets their expectations. This stage focuses on creating a design that is both aesthetically pleasing and optimized for manufacturability.

  • Manufacturing Process

Once the design is finalized, the manufacturing process begins. This stage encompasses the actual production of the components or products based on the approved design. It involves various processes such as machining, fabrication, welding, and assembly, depending on the nature of the product. End-to-end manufacturing production ensures that the manufacturing team deeply understands the design intent, allowing for efficient production planning and execution.

  • Production of Finished Products

The final stage of end-to-end manufacturing production is the production of finished products. This involves quality control checks, finishing processes, and any additional value-added services required to complete the products. Finishing procedures may include surface treatments, painting, coating, or packaging, depending on the specific requirements of the products. The goal is to ensure that the finished products meet the desired quality standards and are ready for distribution or use.

 

Key Advantages of End-to-End Product Manufacturing

By opting for an end-to-end manufacturing approach, companies can reap a host of benefits, each contributing to a stronger, more efficient, and sustainable business model. The following sections look at the key advantages of this streamlined manufacturing method, which range from improved project management and substantial cost savings, to enhanced quality control, customization options, speed-to-market, and adherence to sustainable practices. Let’s explore each of these benefits in detail.

Streamlined Communication and Project Management

Working with a single manufacturer throughout the entire product manufacturing process offers a significant advantage in terms of streamlined communication and project management. 

When multiple manufacturers are involved in a project, communication and coordination can become complex and challenging. Each manufacturer may have different processes, timelines, and priorities, which can lead to misalignment and delays. However, businesses can benefit from a unified point of contact by choosing a single manufacturer, ensuring efficient communication and consistent project management.

A single manufacturer’s integrated approach ensures that the design, production, and finishing teams work closely together throughout the entire manufacturing process. By having all the units under one roof, they can collaborate seamlessly, share information, and address any potential issues promptly. This streamlined communication fosters a deeper understanding of the project requirements and enables real-time adjustments, resulting in a smoother and more efficient production journey.

Cost and Time Efficiency

Project management triangle; Time, Quality, Cost concept. Valuable tool for prioritizing and decision making.

End-to-end product manufacturing eliminates the need to engage multiple companies for different stages of the manufacturing process, resulting in significant cost and time savings. Businesses can enjoy reduced logistical complexities and streamlined processes by choosing the comprehensive manufacturing services of a company like Elemet, leading to cost and time efficiency.

When a project involves multiple product manufacturing companies, each company typically has its own pricing structure and profit margins. Engaging numerous companies for design, machining, finishing, and other manufacturing stages can result in higher costs due to markups at each stage. Additionally, the logistics of coordinating and managing multiple suppliers can be challenging, further adding to the overall expenses.

Businesses can consolidate their manufacturing needs under one roof by working with a single manufacturer. This eliminates the need for engaging and managing multiple companies, streamlining the procurement and production process. As a result, businesses can benefit from cost savings through economies of scale and a more transparent pricing structure.

Furthermore, the reduction in logistical complexities associated with engaging multiple manufacturers can lead to significant time savings. 

Consistent Quality Control

Maintaining consistent quality throughout the manufacturing process is paramount to any successful project. End-to-end manufacturing production offers a significant advantage in quality control. 

With Elemet Manufacturing’s comprehensive services, we ensure stringent quality checks at every stage. Having a single point of contact for quality assurance guarantees that your specifications and standards are consistently met. Our commitment to excellence is what sets us apart as a good manufacturer in the industry.

Greater Flexibility and Customization

End-to-end product manufacturing enables customers greater flexibility and customization options by offering a comprehensive range of services and expertise under one roof. With a single manufacturer handling the entire production process, customers have the flexibility to customize their products according to their specific requirements, whether it’s modifying the design, choosing materials, or incorporating unique features. 

The close collaboration between the design and manufacturing teams allows for real-time adjustments and iterative improvements, ensuring that the final product aligns perfectly with the customer’s vision. This level of flexibility and customization empowers businesses to create tailored solutions that meet their unique needs, fostering innovation and differentiation in the market.

Enhanced Speed to Market

End-to-end product manufacturing accelerates the time to market for products by reducing lead times, expediting prototyping, and streamlining production processes. With a single manufacturer handling all stages of manufacturing, there is no need to wait for coordination between multiple suppliers or deal with potential delays caused by external factors.

The seamless integration between design, prototyping, and production teams enables faster iterations and adjustments, allowing for rapid product development and validation. Furthermore, the consolidated expertise and resources within a single manufacturing facility promote efficient production processes, minimizing bottlenecks and optimizing workflows. 

This enhanced speed to market enables businesses to seize market opportunities, stay ahead of competitors, and capitalize on consumer demand in a timely manner.

Sustainable Manufacturing Practices

End-to-End Product Manufacturing - METAL FABRICATION

In an era of increasing environmental awareness, sustainability is a crucial consideration. End-to-end manufacturing production contributes to sustainable practices. At Elemet Manufacturing, we are dedicated to minimizing waste and optimizing energy efficiency throughout our processes. 

By choosing our services, you align your business with sustainable manufacturing practices, demonstrating your commitment to environmental responsibility.

 

Unlock the Full Potential of End-to-End Product Manufacturing

End-to-end manufacturing production offers a plethora of benefits for businesses seeking comprehensive manufacturing solutions. From streamlined communication and project management to cost and time efficiency, consistent quality control, greater flexibility, enhanced speed to market, and sustainable practices, the advantages are undeniable. 

Elemet Manufacturing stands ready to be your trusted partner, guiding you through the entire manufacturing process and ensuring your success. 

Are you ready to unlock the full potential of end-to-end manufacturing production? Contact Elemet Manufacturing today to discuss your manufacturing needs and experience the benefits firsthand.

Categories
CNC Machining Metal Fabrication Waterjet Cutting Welding

5 Essential Types of Manufacturing Services

Elemet Manufacturing is your go-to-market leader in advanced CNC machining services for aerospace, defense, medical, and industrial equipment manufacturers. Our cutting-edge machinery and specialized team of technicians demonstrate our excellence in precision machining and metal fabrication.

We utilize the latest technology, including 5-axis waterjet cutting, CNC milling, and metal fabrication, among others, to produce high-precision parts with tight tolerances. We provide a full spectrum of solutions in all production areas, from design to engineering and assembly, and can handle machining projects of any size or complexity. Here are the five manufacturing services available at Elemet Manufacturing; reach out to us for more information.

 

CNC Machining Manufacturing Services

CNC machining

CNC or computer numerical control machining uses computer-controlled equipment to produce precision-cut parts and metal components. The CNC machines operate based on programmed instructions, allowing for high accuracy and repeatability in the manufacturing process.

CNC machining controls grinders, lathes, and turning mills to cut, shape, and fabricate various metal parts and models. Machinists or CNC operators use mechanical engineering, technical drawings, mathematics, and computer programming to produce complex designs that are otherwise impossible to achieve with traditional manufacturing methods.

 

5-Axis Waterjet Cutting Technology

5-Axis Waterjet Cutting Technology

5-axis waterjet cutting technology is an advanced manufacturing technique that accurately cuts various materials, including metals, foam, rubber, carpet, plastic panels, glass, marble, decorative stone, and stainless steel. During the production process, the system uses a high-pressure water stream and an abrasive substance to cut through even the most rigid materials with ease.

Abrasive waterjet cutting technology cuts intricate designs with high precision and accuracy. For angular cutting, the system employs a computer-controlled cutting head that moves in five different directions, including X, Y, Z, A, and B-axes. This allows a more precise and efficient cut, as the cutting head can make contact with difficult-to-reach angles and cut through materials with greater accuracy.

Waterjet cutting technology achieves high accuracy levels and detail without damaging the material because the cutting head is adjustable to match the density and thickness of any material. The cutting system can cut through thick sheets of stainless steel without producing thermal damage or distorting the material because the high-pressure water stream cools the material as it cuts.

 

Precision Welding Manufacturing Services

Precision Welding Manufacturing Services

The welding process joins two or more pieces of metal by melting the base materials and adding a filler to fuse the pieces. This manufacturing technique is widely used in the construction, automotive, aerospace, and manufacturing industry. Different base metals are utilized in welding, and various welding processes can be employed to perform many types of welds to produce quality parts.

Aluminum, brass, steel, copper, stainless steel, and titanium are examples of raw metals employed in welding. Modern welding machines are multi-functional and capable of performing numerous welding operations, making them ideal for various applications.

Many types of welds are created using welding processes such as Tungsten Inert Gas (TIG), Metal Inert Gas (MIG), stick, and laser welding. Note the welding techniques used depend on the joined materials, the application, and the required weld quality.

 

Metal Fabrication and Cutting Manufacturing Services

Metal Fabrication and Cutting Manufacturing Services

Elemet Manufacturing offers a wide range of metal fabrication processes, including metal bending, laser cutting, and metal surface finishing, to meet client specifications. We specialize in customized precision metal fabrication solutions, from prototyping to production.

Our team uses state-of-the-art CNC press brakes and tube bending equipment to bend and shape metal with precision, ensuring that each part is consistent and accurate. We employ advanced laser cutting machines to cut through various metals, including aluminum, stainless steel, and carbon steel, for highly accurate cuts.

Elemet’s engineering/manufacturing team has the expertise and equipment to provide one-off prototypes or full-scale production runs and produce highly accurate assemblies that meet quality control specifications. We are committed to providing high-quality, customized precision metal fabrication solutions and metal parts that meet the most exacting specifications.

 

Complementary Manufacturing Services offered by Elemet Manufacturing

Elemet Manufacturing offers complementary surface finishing services, specifically focusing on e-coating and powder coating, both of which significantly enhance the appearance and performance of metal parts. By adding a protective layer to the metal components, these surface finishing applications help mitigate corrosion and boost durability.

Our e-coating process, also known as electrocoating, provides uniform coverage even on complex shapes, ensuring comprehensive protection against corrosion and wear. This technique uses an electrical current to deposit paint or coating onto the metal part, resulting in a high-performance finish that excels in various industrial applications.

We also specialize in powder coating services, which involve applying a free-flowing, dry powder to a metal surface. This powder is then heated or cured along the production line, forming a protective layer that is both decorative and resistant to chipping, scratching, and fading. The powder coating process provides an attractive, durable, high-quality finish that enhances the lifespan of the metal part. 

 

Partner With Elemet Manufacturing for All Your Machining Needs

Elemet Manufacturing employs top-of-the-line machines to provide waterjet cutting, CNC machining, precision welding, and metal fabrication and cutting services in the industry. Thanks to our high-quality welding equipment, we can work with a variety of materials, including titanium and steel.

Companies requiring metal bending, cutting, and assembly can rely on our custom metal fabrication and laser-cutting manufacturing services. Contact Elemet Manufacturing today and request an estimate of your machining project.

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CNC Machining

The Top 5 Benefits of CNC Manufacturing

CNC manufacturing is a versatile technology that finds applications across numerous industries, including agriculture, aerospace, and more. It is particularly suitable for situations where accuracy, time, and cost-effectiveness are essential factors in the production of components. The art and science of CNC manufacturing are continually evolving, offering great benefits of CNC manufacturing to meet the ever-increasing demands of modern manufacturing.

CNC (computer numerical control) was first used by the United States Air Force at Wright Patterson Field in Dayton, Ohio, to mass-produce helicopter blades during WWII. Mr. John Parsons and Mr. Frank Stulen developed a process to use numerically controlled machinery to fabricate helicopter blades, prioritizing accuracy and mass production.

CNC manufacturing has come a long way since those early days. By partnering with Elemet Manufacturing, an industry leader in CNC manufacturing, you can benefit from our cutting-edge technology and expertise.

Elemet Manufacturing’s state-of-the-art CNC machines can help you meet your manufacturing needs precisely and efficiently. Learn more about the benefits of CNC manufacturing below, and then contact us today to learn more about our CNC manufacturing services.

 

The Cost-Effective Benefit of CNC Manufacturing

The amount of labor involved in CNC manufacturing, as opposed to traditional machining of parts, is a game-changer. Unlike traditional manufacturing processes where several highly trained employees must operate lathes, drills, and presses, a single qualified CNC machine operator can oversee the CNC manufacturing of several machines simultaneously, reducing labor costs and increasing productivity.

Additionally, CNC machines operate at higher speeds and with greater precision, resulting in faster production times and improved manufacturing timelines. These cost-saving benefits make CNC manufacturing an ideal choice for applications where speed, accuracy, and cost-effectiveness are essential factors in producing components.

 

The Faster Production Time Benefits of CNC Manufacturing

Production Time Benefits of CNC Manufacturing

Using CNC manufacturing eliminates the need for time to build a prototype. CNC manufacturing creates a ‘digital twin’ using the same software and technology to operate the machine and produce the part.

This significantly cuts down the production timeline, so your focus can be on the next step in your component’s construction process.

So far, we have seen money saved and a faster-produced part. If the benefits ended there, your company would already save time and money, two big factors in any industry!

Now let’s look at how much better the accuracy will be in taking your raw material and producing a finished part using CNC manufacturing methods.

 

The Accuracy Benefits of CNC Manufacturing

One of the most significant benefits of CNC manufacturing is its unparalleled accuracy and precision. CNC machines are designed to execute highly precise machining operations with exceptional consistency, ensuring that each component is identical to the last.

CNC machines can easily produce complex shapes, intricate designs, and tight tolerances, which can be challenging or impossible to achieve with traditional manufacturing methods.  

Additionally, CNC machines can automate various processes, reducing the likelihood of human error and minimizing the risk of defects. This accuracy and precision translate into superior-quality finished products, increased efficiency, and, ultimately, satisfied customers.

Some of your components may require intricate cuts or shapes, bringing us to another benefit of CNC manufacturing.

 

The Complexity Benefits of CNC Manufacturing

CNC manufacturing

In traditional manufacturing methods and machinery, intricate cuts, shapes, and textures can increase manufacturing costs. Sometimes these attributes are simply not obtainable when using traditional machinery and manufacturing.

With computer programming, CNC machines can easily create complex shapes, intricate designs, and tight tolerances, which can be challenging or impossible to achieve with traditional manufacturing methods. CNC manufacturing is the ideal machining solution if your component has intricate design details.

Now let’s turn to the safety benefits of CNC manufacturing.

 

The Safety Benefits of CNC Manufacturing

Firstly, safety measures implemented during CNC manufacturing reduce the risk of product defects and errors, ensuring that the finished products you receive are of high quality and meet the required specifications. 

Secondly, safer manufacturing processes minimize the risk of production delays caused by accidents or injuries, resulting in faster turnaround times for your orders. Finally, by partnering with a CNC manufacturing company that prioritizes safety, you support a responsible and ethical business that values its employees and takes the necessary steps to ensure a safe working environment.

 

When is CNC Manufacturing Right for You?

CNC manufacturing is an ideal choice for applications where precision and consistency are essential factors in the production of components. CNC machines can execute highly precise machining operations with exceptional consistency, resulting in components that meet tight tolerances and specifications.

Additionally, CNC machines are designed to automate various processes, reducing the likelihood of human error and minimizing the risk of defects.

For applications where flexibility and versatility are essential factors in the production of components, CNC manufacturing is again an ideal choice. Capable of executing a wide range of machining operations, from drilling and milling to turning and grinding, CNC machining is versatile and adaptable to various manufacturing requirements.

Additionally, CNC machines can be programmed quickly to produce multiple designs, allowing for greater customization and adaptability to changing manufacturing needs.

 

Which CNC Manufacturer is Right for You?

CNC manufacturing has evolved significantly since the US Air Force first used it to manufacture helicopter blades during WWII. Today, CNC manufacturing finds applications across numerous industries, including aerospace, automotive, medical, and more.

Its versatility and precision make it an ideal choice for applications where accuracy, consistency, and efficiency are essential factors in the production of components.

With cutting-edge technology and skilled craftsmanship, Elemet Manufacturing can help you achieve your manufacturing goals with precision and efficiency. Whether you require high-quality prototypes or large-scale production runs, their team can provide the expertise and support you need to succeed.

Contact Elemet Manufacturing today to learn more about their CNC manufacturing services and how they can help you meet your manufacturing needs.

Categories
CNC Machining

Understanding CNC Machines: What They Are and How They Work

What are CNC Machines?

CNC, or Computer Numerical Control, is a manufacturing technology that utilizes a computer program and specialized, automated tools in subtractive manufacturing processes. The term “computer numerical control” refers to the methodology used to carry out the manufacturing process rather than the specific function performed by the CNC system.

Unlike a 3D printer, which adds material on top of the material to create a “printed” item, subtractive manufacturing removes material from a blank or workpiece. 

Various factors must be considered to program the complex cuts and produce a usable and consistent product, such as the type of material used, the optimal cutting techniques, the required speed, and other relevant parameters. Elemet, a leading fabrication company, employs advanced machinery capable of operating on a broad range of axes to achieve optimal results in milling and other manufacturing processes.

The only limit to what our machines can do is your imagination. The uses of CNC machines are in fabrication, biomedical, food service, prototype creation, small business manufacturing, and large-scale industry. CNC machines can fabricate difficult-to-find mechanical parts and millstones and produce finished products for consumer use.

Computer Numerical Control

CNC machines

CNC machines use a programming language that understands the function of the various machine tools, the machined materials, and their composition and compiles them to complete the job. G-Code is the most common programming language, and machinists input each function that needs to be done as a line of code. 

The machine carries out each step as directed with extremely low margins of error and variation. Since computers can function perfectly, CNC coding is used for assembly line work, where multiple products can be nearly identical throughout the project.  

Materials

CNC machining can be performed on a broad selection of metals, including both ferrous and non-ferrous materials. Some of the most commonly used metals in CNC machining include: 

  • aluminum, 
  • brass, 
  • copper, 
  • stainless steel, 
  • titanium, and various types of steel, such as mild steel and tool steel. 

Additionally, specialty alloys like Inconel and Monel may be used for specific applications. The selection of a specific metal will depend on the required properties of the finished product, such as strength, weight, corrosion resistance, and thermal conductivity, among other factors.

Types of CNC Machine Tools

Computer numerical controlled printer, 3D milling machine and other thematic symbols.

Subtractive manufacturing involves using various cutting tools to remove material from a raw workpiece or blank. The blank is secured within the CNC machine. A series of control arms, laser guidance systems, and pre-programmed cuts and angles are used to shape the material according to the desired specifications. 

The computer controls the movement of the cutting tools to ensure precise and accurate results. By carefully removing material from the workpiece, complex shapes and intricate designs can be achieved with exceptional precision and accuracy. The selection of the specific cutting tools and parameters will depend on the type of material being machined and the required specifications of the finished product.

Here are the most common CNC machine tools.

  • Mills: Milling involves using precision routers, drills, and other cutting tools to remove material from a workpiece according to a pre-programmed course. By rotating the workpiece on an axis, the cutting arms of the mill can operate on a grid pattern, allowing for 3D subtractive fabrication.
  • Lathes: Lathes are machines that rotate blanks at high speeds while using indexing bits to remove material and shape it relative to the die and required cut. This process, also known as turning, can produce prototypes and finished products with low degrees of tolerance on various materials, including aluminum, steel, copper, bronze, brass, titanium, zinc, and wood.
  • Plasma cutters: Electrical arcs and pressurized cutting gas vaporize blank stock with precise cuts. The CNC program factors the workpiece’s metallurgical properties, speed, and dimensions to make cuts requiring minimal finishing. Plasma cutters operate at temperatures higher than the sun’s surface, and using different types of cutting gas can direct the plasma with high precision. Not ideal for temperature-sensitive materials.
  • Waterjet cutters: A precision tool, waterjet cutters use highly pressurized water jets focused through a jewel orifice, usually made of ruby or diamond. The water speed travels twice the speed of sound, and sometimes a garnet abrasive is used to affect the size and depth of the kerf or cut. The erosive properties of the water jet can cut through metal without affecting the temper or causing thermal zones, unlike plasma cutting tools. Waterjet cutters can cut plastic without melting it and glass without shattering it. Also, use waterjets to cut stones such as granite, quartz, and marble, and you can configure them to be used in commercial kitchens to cut food with high precision.
  • Lasers: A very versatile machine tool that uses focused light and cutting gasses to control kerf size and reactivity. Pulse laser cutting minimizes heat and can make cuts with minimal depth, not much larger than the beam size. Lasers cut various materials, including metal, wood, and plastics. 

Milling Machine Operation

CNC machines rely on a programming language to determine the fabrication process based on the selected tool and its operation. Skilled CNC milling operators are trained to create programs in the required programming language, which may only sometimes be G-Code, to execute the machining operations accurately. The quality of the program and operator proficiency are critical factors in determining the final product’s quality.

When performing CNC milling, various factors must be considered in determining the appropriate machining process, such as the size of the blank, required cuts, materials used, the time required to make the cuts, and the milling speed.  

CNC machines can operate with extremely high precision and low degrees of tolerance, making them suitable for a broad array of industries, including aerospace, automotive, defense, electronics, medical, and telecommunications. By ensuring that each cut is consistent, CNC machines can be utilized in both mass production and prototype building, producing high-quality and precise finished products.

Manufacturers utilizing CNC machines offer customers numerous advantages, including precision, speed, and consistency. CNC machines enable manufacturers to produce high-quality products efficiently, reducing waste and overhead costs associated with traditional manufacturing methods that require multiple machines and machinists to accomplish the same tasks.

Additionally, CNC machines offer unparalleled versatility, allowing manufacturers to perform a broad range of machining tasks with a single tool. This, in turn, results in faster turnaround times, improved quality control, and, ultimately, increased customer satisfaction.

Elemet Manufacturing offers a wide range of CNC milling machines equipped with cutting-edge technology to efficiently and effectively mill a variety of materials, resulting in high-quality finished products for our customers. For more information, or if you have questions about how to get started, visit our website and contact us today to step into the future of fabrication with CNC machines.

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CNC Machining

5 CNC Milling Techniques for Your Best Designs

The tensile qualities of metal make it one of the most exacting materials to work with. This difficulty also poses a significant challenge to producing detailed and accurate components. Traditional methods just couldn’t keep up with the tighter tolerances that modern engineering calls for.

This is where CNC milling techniques come in. Today, it is among the most common metal-working industrial processes. While others, such as laser and plasma, represent cutting-edge technology, they can’t simply stand up to the capability and complexity a CNC mill can deliver.  

To best understand CNC milling techniques, let’s take a look at what it is and how to use them. When you need accurate production on complicated designs or have a fabrication issue that needs to be solved, contact Elemet Manufacturing. We provide innovative solutions for manufacturing problems of all shapes and sizes.

What is CNC Milling?

CNC milling is a machining process that uses computer-controlled rotary cutting tools to remove material from a workpiece. The milling process can be used to create custom parts and prototypes from a variety of metals and other materials.

CNC milling machines are generally more accurate and efficient than traditional machining methods, and they can be used to create complex shapes that would be difficult or impossible to produce with other methods.

CNC milling is an essential machining technology for the modern manufacturing industry.

CNC Milling Techniques

As you can expect, there are various ways in which a CNC machine can achieve the various designs you create. You begin with a computer-aided design (CAD) or 3D model of the component you want.

The software then translates the model into a machine-readable form, which the Computer Numerical Control reads. The CNC mill carries out the instructions and uses different paths and movements to achieve the product. To accomplish your goal, a CNC machine may use the following techniques. 

1. Surface or Plain Milling

As the name suggests, the CNC machine employs various tools to subtract material from the surface of the item it is machining. During this process, the mill’s rotation axis moves parallel to the work item. 

The type of tool you use depends on the outcome you are expecting to achieve. If you’re looking for a quick outcome, use a wide cutter to remove material from the workpiece quickly. The result, however, may not be the finish you are looking for. 

To get a finer finish, it’s best to utilize a tool with finer teeth. You end up using fast cutting speeds and slow feed rates. The outcome is well worth the effort. 

2. Face Milling

industrial metalworking cutting process by milling cutter

When using the face milling technique, the machine’s rotational axis will be perpendicular to the surface of the workpiece. The tool faces the workpiece face down for the express purpose of removing material from it. 

It would be best if you relied on face milling for more intricate contours with a fine finish. The results tend to be superior in comparison to plain milling because the side teeth do the cutting while the tip teeth do the surface finishing.

3. Angular Milling

The angle milling process the metal plate part by flat end mill tool.

The cutting tool in this technique faces the workpiece’s surface at an angle. If your design has angular cuts such as dovetails or grooves, then this technique will take care of them quite easily. 

If you’re using a 3-axis mill, putting different cutters should be the way to go. You can count on dovetail cutters to attain angled grooves and a conical cutting head if you’re looking for chamfering. 

4. Form Milling

Form milling is your go-to technique when you want to get radii, counters, or curves. You employ different cutting tools to achieve specific accuracy for each detail you’ve worked into your design. Therefore, you spend less time switching between cutting heads.

Done right; you can realize the non-flat cuts in a single session. The tools can help you obtain various outcomes, such as round edges and recesses. They’ll need to be the appropriate tools to attain the result you want as accurately as possible. 

5. Profile Milling

CNC Milling Techniques

For concave or convex designs, it takes a three-step process to get desirable outcomes. These are rouging, half-finishing, and final finishing. For a proper profile milling session, use round inserts for the roughing and then ball-nose end mills for the semi-finishing and finishing steps of the process.  

Do You Need Advanced CNC Machining Services?

Then look no further than Elemet Manufacturing Services. We have been a market leader in providing innovative solutions for problems facing manufacturers all over the globe. We are a joint venture between Precision Waterjet Concepts and Aitkin Iron Works that merged; we provide you with over 100 years of experience.

Not only do we provide advanced CNC machining services, but we also offer 5-axis waterjet cutting, painting, welding, and other solutions. Our combined knowledge and experience make us a manufacturing powerhouse.

Let our team solve your manufacturing problems. Get in touch with us today.

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CNC Machining

When to Use CNC Milling

What Is the Metal Fabrication Process?

Metal fabrication is the process of cutting, forming, and assembling metals to create structures or individual parts. The cutting process involves using tools to remove material from the workpiece and can be done either manually or with a machine.

Welding joins two pieces of metal together and can be done using various methods such as oxyfuel welding, tungsten arc welding, and resistance welding.

CNC milling is a machining process that uses computer-controlled cutting tools to remove material from the workpiece. The metal fabrication process includes additional steps such as surface finishing, heat treatment, and assembly.

The following is a brief description of various metal fabrication processes and a more in-depth look at when to use CNC milling.

Contact Elemet Manufacturing to learn more about the wide range of metal fabrication services available, including precision waterjet cutting, welding, and CNC machining.

Cutting

Metal cutting is a manufacturing technique that uses a sharp tool to remove material from a metal workpiece. You can use this method to create everything from simple objects like coins to complex pieces like car engine components.

In most cases, the metal workpiece is a sheet that is first cut into smaller pieces using a saw or laser cutter.

Once you have cut out the desired shape, the parts are welded or fastened together to create the final product. Metal cutting is an essential manufacturing technique used in many industries.

Folding

Folding requires shaping a metal surface at a specific angle. It is one of the most challenging methods of fabricating metal components. It is a technique unique from metal bending and limited by geometry and tonnage.

Intricate, acute bends are often not possible as the folding beam has to be able to reach the bend without running into other surfaces on the component. When a folding machine cannot exert enough force, that is when a press brake comes into play.

Metal folding is frequently used in the manufacturing of automotive parts, food packaging, and appliances. It is an efficient and cost-effective way to create strong and durable products.

Welding

Welding is a metal fabrication process that involves joining metal parts together by heating the materials to their melting point, which fuses them when cooled. Several different welding methods include laser welding, TIG welding, MIG welding, and stick welding.

Each method has its advantages and disadvantages, and the best choice for a particular project will depend on the material selection, the desired strength of the joint, and the budget. 

Machining

Factory Asian male worker

Machining involves removing material from a workpiece to create the desired shape or finish and is performed using various tools, including lathes, mills, and routers. Machining is generally divided into two categories: subtractive and additive.

In subtractive machining, material is removed from the workpiece, while additive machining, on the other hand, involves using 3D printing technology to build up the desired shape layer by layer. 

Punching

This method uses a drill to punch holes in metal placed beneath a die by drilling through it. The circumference of the drill must be small enough to fit appropriately through the die for the punch to be effective.

The scrap slug produced as a result of the operation may be thrown away or recycled. Slugging is another name for stopping short of punching through the metal when making things out of metal.

Shearing

Shearing is when sheet metal is cut into pieces using power-driven blades. It is commonly used to cut metal plates, sheet metal, or metal tubing. Shearing is a quick and efficient way to produce parts with a high degree of accuracy.

However, it can also produce burrs and sharp edges, which you must remove before having a usable piece. Metal shearing is an important process in many industries, including automotive, aerospace, and construction.

Stamping

The metal stamping process is a manufacturing method that uses dies to form complex parts from sheet metal. In contrast to punching, the goal is typically to form a shape in the metal and not punch through it.

The process can produce varied shapes and sizes and is well suited for mass production. The metal stamping process is an efficient way to create parts with complex shapes from sheet metal.

Casting

Casting is a process in which you heat metal until it liquefies and pours it into a mold. The metal takes the shape of the mold as it cools, and once it has cooled completely, you break the mold to reveal the finished product.

Casting is often used to create metal objects with complex shapes that would be difficult or impossible to create using other metal manufacturing methods. You can also use casting to produce large metal objects relatively quickly.

What is CNC Milling?

CNC milling technology

CNC (computer numerical control) milling gradually removes material from the workpiece using rotating multi-point cutting tools and digital controls. This technique creates a specific part or product tailored to the customer’s specifications.

This method can machine many materials, including metal, plastic, glass, and wood, and create a vast range of goods and parts with unique designs.

CNC milling, drilling, turning, and others are mechanical processes in which material is removed from the workpiece mechanically, such as by the actions of the milling machine’s cutting blades. CNC milling technology is one of the most dependable ways to make parts from various materials.

Benefits of CNC Milling

The most notable benefits of utilizing CNC milling technology are outlined below.

Precision

Manufacturing parts precisely to specifications is one of the main benefits of using CNC milling machines. The danger of real-time human error, common in manually run machines, is eliminated by CNC mills. 

CNC mills depend on pre-programmed computer instructions, which can be reviewed and checked for accuracy before production. You can form complex pieces accurately with tolerances as tight as 0.004mm.

Efficiency

Conventional milling machines may require an operator to change the cutting tools manually depending on the work required. It is time-consuming and ineffective because it allows for human error during the changeover procedure.

On standard CNC mills, rotating carousels can usually store up to 30 different tools. These instruments are automatically replaced on the spindle during machining operations, allowing you to complete cutting activities more quickly and accurately.

Automated tool changeovers and pre-programmed instructions can reduce fabrication time from days to a few short hours.

Wide Range of Material Options

CNC mills are compatible with many materials, including plastics, metals, and composites. If you have blocks of the material to mill, CNC mills will have no trouble with it.

High Rate of Production

Because CNC milling is an automated operation, the cutting tool can transition through procedure steps more quickly than humans. The actual cutting rates are limited by the design and materials used. It still creates a higher output rate than most other manufacturing methods.

Affordability

CNC milling is an accuracy- and speed-oriented technique that you can use to produce parts with complex shapes. It is also relatively affordable, making it a popular choice for both prototyping and low-volume production runs.

When choosing a CNC milling service, it is important to consider the accuracy and speed requirements of the project, as well as the cost. By carefully selecting the right CNC milling service provider, it is possible to produce high-quality parts at a reasonable price.

Choose the Right Method for Your Project

Metal fabrication requires sophisticated tools and expertise. Elemet Manufacturing has developed expertise in many metal fabrication techniques for various commercial and industrial applications.

Call us today if you need more information about a specific metal fabrication method or want to know which one is appropriate for your project.

Categories
CNC Machining

EMI MEANS QUALITY CNC MILLING MACHINE SERVICES

The most frequently used CNC machining service for metalwork is CNC milling machine services. Milling is a high-demand service for OEM’s due to their increased need for parts with geometric complexity. CNC milling tools perform drilling and cutting machining processes. CNC milling machines and tools are incredibly versatile and produce custom, precision parts for a wide variety of industries and applications.

Three things an OEM requires from a CNC Milling Machine service

Precise CNC Milling

 

Precision

Precision is essential to part quality. OEMs have specific tolerances, and design parameters that every part ordered must meet to fit smoothly into the overall project upon assembly. In addition, most parts require machining on multiple surfaces at various angles with precise dimensions. EMI’s team of highly skilled CNC craftsmen have the experience and expertise needed to produce close tolerance components with precision accuracy.

Speed and Efficiency

CNC milling machines are best suited for running parts in production quantities. A conventional CNC can sometimes take hours to set up. However, more modern CNC machines are designed to minimize setup time. A full-service CNC machining service such as EMI maximizes efficiency and minimizes operator error by investing in experienced craftsmen and modern CNC milling machines.

Quality control

All reputable CNC machining services check their parts. However, those CNC milling machine services that go above and beyond “checking” stand out from the rest. Having an ISO 9001:2015 certification helps ensure that products consistently meet requirements and quality is routinely managed.

Elemet Manufacturing machines custom CNC parts for clients of all sizes in a wide variety of industries. Our clients trust us to deliver high-quality parts that meet their precise specifications fast. Interested?

The CNC milling machine is the heart of the precision CNC machining process.

Man Programming CNC Milling Machine

One of Elemet Manufacturing’s core service offerings is CNC milling machine services. CNC milling machines use computerized controls and translated codes from CAD and CAM software to perform automated machining functions on the raw metal stock.  Metal sheets or blocks are placed in a vise on a table below a spindle that spins rotary cutting tools to remove excess material from the raw metal as it is fed into the milling tool.

The main parameter that determines the capabilities of a milling tool is the number of axes. A basic 3-axis CNC milling machine has three movement axes. X=Left to Right.  Y = Forwards and Backwards. Z = Up and Down. The three axes of motions let the spindle spin a cutter at high speed to carve away material to create unique shapes, slots, holes, and details in a part. The type of cutting tool defines the shape of the part.

Horizontal and Vertical Machining provide efficiency and speed.

Horizontal CNC Milling Machine

Many machine shops use only one type of milling center. Our horizontal and vertical milling centers provide very different sets of advantages. An OEM or designer’s project shape, part volume, and required machining features benefit from the versatility and efficiency of dual machining mill types. In addition, our vertical and horizontal mills transform complex manufacturing processes into a single setup providing faster turnarounds and cost-efficient CNC machined parts.

A Vertical CNC milling machine features vertically-oriented tooling with rotating cylindrical cutters that can move along vertical axes to make plunge cuts and drilling. It is instrumental in die sinking.  This design makes them suitable for end milling operations, which use tools with teeth on the periphery and face.

A vertical CNC milling machine is ideal for:

  • Box type parts, such as gearboxes, spindle boxes, and gear pump shells
  • Complex curved parts, such as cams and mold cavities
  • Specialty or irregular parts, such as brackets and braces

Horizontal CNC milling machines have horizontally oriented tooling with rotating cylindrical cutters that can move along horizontal axes to create the shapes, slots, details, and holes of a part. As a result, they have faster processing speeds and can produce complex components in fewer operations.

A Horizontal CNC milling machine is ideal for:

  • Large or heavy parts with expansive surface areas
  • Specialty or irregular parts
  • Components that require machining on multiple sides
  • Applications that call for slots, grooves, pocketing, and facing

A 4-axis CNC milling machine service provides precision machining of complex parts. 

4-axis CNC Milling Machine

EMI offers 4-axis CNC milling machine services that can cut part geometry and complex or intricate shapes that other machining methods can’t match. By combining several stand-alone operations into one, the service can achieve:

  • Increased Accuracy
  • Reduced Part handling
  • Eliminating Multiple setups
  • Reduced Cycle time
  • More Efficient Production

The spindle head on a 4-axis CNC milling machine operates closer to the workpiece, which permits:

  • use of shorter cutting tools with less vibration
  • operation at higher cutting speeds
  • tighter tool movement
  • improved surface finishing

When a 3-axis CNC milling machine cannot accomplish the part complexity the client requires, a 4-axis CNC milling machine is an efficient, high-quality solution. 

Applications for CNC Milling Machine Services

CNC milling is especially valuable for producing large parts that demand significant floor space, such as aircraft and aerospace panels or components. It also supports projects for:

  • Commercial applications
  • Building and maintenance
  • Electronics
  • Medicine
  • Security
  • Recreation
  • Transportation
  • Automotive
  • Industrial and O.E.M. 

The Advantages of CNC Milling Machine Services

The most significant advantage of CNC milling machine services is processing almost any kind of metal material. CNC milling can process all types of steel, titanium alloys, aluminum alloys, tungsten, copper, bronze, and iron. Elemet Manufacturing Inc. offers cost-effective, quality CNC milling machine solutions. EMI provides:

  • Production of complex parts
  • Cost-effective prototyping
  • Short-run production
  • High dimensional tolerances
  • Smooth finishes
  • Variety of materials
  • Cost Efficiency
  • 100% quality
  • Quick turnaround times
  • Superior customer service

The key to fast, quality custom CNC milling machine services is working with the right partner.

Working with an experienced one-stop CNC machining services shop will provide you the most cost-efficient, quality custom CNC milling machine services for your project. Elemet Manufacturing Inc. is an ISO 9901:2015 certified one-stop machining company providing quality services.

We offer innovative solutions to the OEM industry and eliminate the need for external sourcing, saving you time and money. In addition to our CNC Milling Services, we provide:

  • CNC turning, threading, and machining
  • 5-axis waterjet cutting
  • Welding
  • Fabricating
  • Assembly
  • Inspection

We are part of the Elemet Group, offering innovative, one-stop metal fabricating, CNC machining, and industrial coating solutions since 1947. Our sister companies are:

We stake our reputation on providing the highest quality and customer service. Contact us today to learn more about EMI’s CNC milling machining services or receive a free estimate on your next CNC machining project.

 

 

 

 

 

 

 

 

 

 

 

 

Categories
CNC Machining Metal Fabrication

Prototyping With A “Cold” Manufacturing Process

Choosing the right metalworking partner for cold-forming metal can be a critical decision. You rely on them to get a prototype produced. However, if you choose the wrong partner, there can be problems.

For instance, the inherent properties of metal present challenges. Metal tends to change its shape, area, volume, and density in response to a change in temperature. As a result, it may easily deform when being processed into your prototype.

To ensure complete satisfaction, you need to choose a CNC machining services provider with experience in the cold manufacturing process.

Because no heat is added to the material, cold-forming sheet metal allows for high speed, precision, and quality production. 

Elemet Manufacturing Inc. (EMI) has decades of experience. We’re an industry leader in custom, extensive work envelope CNC machining services for prototyping and production runs. 

Count on CNC’s machining processes to meet the highest standards of quality and efficiency for cold forming and prototyping. 

EMI is an ISO 9001:2015 certified company.

What Is The Prototyping Process 

workers examining prototype Bringing a new product to market involves the design, market research, and manufacturing of your product. 

Prototyping is the part of this process where a working model of the product is made and tested. A manufacturer can make a prototype from the same material as the end product. You can use an alternative material for the prototype for testing purposes.

A sheet metal prototype is a model of a metallic product. Your prototype is built according to your design to test your concept or process. In addition, it provides you with a physical sample that can be replicated. 

For your product to be a success, you need to start with an excellent prototype model. 

A Short Overview Of Metal Cold Forming Processes

Cold forming is the process of forging metal below its recrystallization temperature. It is shaped at near room temperature.

The scope cold forming uses is wide and varied. It includes complex shapes such as riveted joints, screw heads, threads, and a vast number of other applications.

Cold-forming techniques are often split into four categories: squeezing, bending, drawing, and shearing. 

The cold-forming process uses the pressure and speed of a mechanical or hydraulic press. The press takes a metal ‘blank’ (a flat piece of metal) and shapes it using a ‘punch’ and ‘die’ set. Basically, the punch is the tool used for shaping, and the ‘die’ is the clamp that holds the metal.

The metal blank will form around the punch as it’s hammered into the die. The blank takes the correct shape without material waste. 

This process is all carried out at room temperature and is known as cold forming or cold forming sheet metal.

Cold forming can be used on a variety of metals, including aluminum, copper, brass, steel, and stainless steel.

cold form process

Advantages Of Cold Forming Process For Prototyping 

The cold-forming process has several advantages, including higher production speed, minimal material waste, and a more robust end product.

High-Speed Production

Because high temperatures are not used on the metal material, cold-forming allows for high-speed production, around 100 parts per minute. In addition, the cold forming process eliminates the need for several additional machining operations. This reduces the time needed to complete the manufacturing process.

Little Material Waste

The high percentage of material utilization in cold-forming means that material waste is significantly reduced, if not eliminated.

Traditional metal manufacturing processes, due to offcuts, etc., can generate significant waste. For example, cutting, milling, and grinding can result in 80% or more of the original material being converted to waste.

In stark contrast, cold forming uses 100% of the original material.

Cold forming brings benefits that are both environmental and financial. There are considerable cost reductions that the process of cold-forming metal can achieve.

Stronger End Product

All the original material is used. The metal is stretched beyond its yield strength but with no adverse effect on its tensile strength. 

Because there is a restructuring of the material grain as the part is formed, the result is improved tensile strength. 

The metal becomes more rigid and stronger, much like a sawn piece of timber becomes stronger along its length.

cold forming threads

Disadvantages Of Using A Cold Forming Process

There are some disadvantages of cold forming sheet metal, including:- 

  • A more limited variety of metals for which the process is effective 
  • A lesser scope of shapes and forms that can be achieved 
  • Higher setup costs 
  • Greater manufacturer experience is required to be successful

Limited Metal Types

The main disadvantage of cold-forming sheet metal is that the process cannot be used for every type of metal. The reality is that some metals are more likely to crack. For instance, certain steel types with a .5% or above carbon content cannot successfully withstand the process. 

Limited Shapes And Forms

Another disadvantage is that cold forging can only create specific shapes. Those shapes are usually more basic and mass-produced. If you’re looking for a custom metal piece, a different process will probably work better for your desired outcome.

Higher Setup Costs

High production quantities are required to justify the high setup costs of cold-forming sheet metal. Quantities of 25,000 to 100,000 per year are needed.

Greater Experience Required

Compared to hot forming, the loads required to deform material are high and material deformability is low. A team with a  high degree of manufacturing experience is needed to achieve complex geometries.

What conclusion do you come to after this consideration of cold-forming and prototyping?

You can likely see the many advantages of cold-forming your prototype and have learned some potential pitfalls. Indeed, choosing the right metalworking partner for cold-forming metal can be a crucial decision. That’s particularly true if you rely on them to get a prototype produced.

For peace of mind, trust the expert team at Elemet Manufacturing to care for your cold forming and prototyping needs. Contact us today!