All the Pros and Cons of Rapid Prototype Machining and Turning

Over the years, manufacturers have turned to CNC milling and tuning to create custom prototype parts. Computer Numerical Control techniques are accurate to 0.0005 inches and can create intricate 3-dimension parts working off of a digital design.

HOW EXACTLY DOES THIS PROCESS WORK?

Lathes and drills from the CNC machine are controlled through a computer’s inputs. The entire process starts off with a 3D digital design. These designs are made using CAD software by a designer who inputs a series of G-codes.

This G-code is sent to the lathe machines, giving it the instructions of where to cut a piece of material. The piece of material is usually a slab or a block of which the machine cuts away parts of. Resulting in a quickly made prototype of a part that can be used in many different areas of life, especially for prototype cnc parts that require high precision and fast turnaround.

This process is much more time efficient and accurate as it eliminates the time and handwork of a manual machinist operating with hand tools.

To create a rapid prototype, makers are turning to CNC methods as it is much faster. By using different techniques, a scaled model or prototype is quickly fabricated. These models can either be assembled to assess or adapted for further tests. Read this to learn more about prototype production.

Now that we know what Rapid prototype and machining is, let’s look at all the pros and cons of the process.

ADVANTAGES

Apart from the speed of production, there are many other advantages to companies considering using a machine shop. Here are our top advantages:

From Dream to Reality

The biggest advantage, and ultimately the purpose, is the CNC machine’s ability to take a file and turn it into a prototype. The digital process allows the designer to create an intricate part which is later read by the machine as a computer file.

Once created, the part will almost be an identical replica of the 3D design. Dimensions will be accurate and the prototype will include all the curves, lengths, widths, and crevices that was part of the original computer design.

Easy Fixable

Once the prototype has been created, it’s very easy to determine where there are any mistakes in the design. Designers can return to the CAD software and make easy alterations in the same design, until they reach the desired outcome.

An even greater advantage is that all prototypes can be compared to each other side by side. Making it easier to spot flaws and do further testing.

Consistency and Quality

Computer-controlled machinery tools function extremely accurate and precise. Trying to create the exact same product without using molds or machines can be extremely tricky and inconsistent.

Where manual artisans have to use accurate measurements and tools, it can be difficult to create a few of the same parts without a few of them being slightly off of the correct measurements.

CNC machines are designed to follow instructions to the exact fraction of a millimeter. Giving the maker a precise prototype time after time.

At first, makers will only request one prototype as an example piece. But after that, the machine shop will have to produce hundreds or even thousands of the same product. Knowing that a machine is in charge of the re-production can give you an ease of mind, there won’t be any deviation from the original agree-upon design.

Even though the machine will be overseen by a quality expert operator, the equipment will do all the hard work ensuring quality and consistency.

Material Choices

Trying to carve and chisel into a piece of very strong steel can almost be impossible. It’s guaranteed that the artisan won’t have the perfect end result. Compared to CNC machining where makers can choose from a variety of different strong materials.

3D printing is a great first choice if your product doesn’t require a strong material, but if it does, then you have to consider CNC machining and turning. It offers a much wider variety of durable and strong material. Here are the common materials used with this process:

Plastics – ABS, PC, POM, LDPE, PMMA, PAGF30, PS, PP, PCGF30, TEFLON, LDPE, and HDPE

Metals – Aluminum, Copper, Bronze, Stainless Steel, Steel, Magnesium, Titanium, Brass, and Zinc

Within the above-mentioned materials, there are wide ranges as well. The ranges within a certain metal is dependent on thickness and cost.

Exact Replica

Another great advantage is that CNC machining creates prototypes that are extremely similar to the final desired part. If you want an exact prototype replica of what the end result might look like, then you can request it from the quick turnaround machine shop. Using the exact same materials and design that would be used in your end design.

This will give the maker a broad idea of how much exactly costs of manufacturing will cost and whether the end product will be functional. It’s easier to move onto the next step in the process, when the prototype is almost an exact replica of what you are looking for.

DISADVANTAGES

There are only a few disadvantages of using CNC machining and turning.

Expensive

The process of CNC machining is much more costly compared to 3D printing. This is because machines are much bigger, more intelligent, and intricate than 3D printing machines. They also require expert human supervision and higher-quality materials.

Even though the initial process is much more costly, engineers can safe time during the rest of production.

Material Waste

Because this process uses a subtractive process and not a building one like with 3D printers, it does cut away a lot of material. Metal chips and material shavings will have to be disposed of after the production. For this reason, CNC machining is also more expensive.

Some Restrictions

Most common machines used are built on a 4-axis and 5-axis base. They offer great geometrical flexibility with only a few limitations. These limitations come in to play when prototypes feature intricate angles and grooves that requires extra cutting tools.

It is safe to say that CNC machining and turning provides makers with excellent advantages overshadowing all disadvantages when creating prototypes.