The manufacturing industry is currently undergoing a digital
transformation, in which new business models are being engineered to improve
time to market as a means of meeting customer demand for more instant services
and products.
In order to thrive in this Fourth Industrial Revolution, businesses are
challenged with having to continually reimagine processes and production
methods. Many are embracing the latest in digital manufacturing processes,
arguably the most well-known of which is 3D printing.
With news of 3D-printed medical devices, human organs and even components
of 3D printers regularly making the headlines, there is less discussion around
other equally important digital manufacturing processes, such as CNC
machining.
Using automated software to control high-speed milling and turning tools,
CNC (computer numeric control) machining is a crucial digital manufacturing
service for a range of industries, delivering fast turnaround of parts and
prototypes.
Although CNC machining itself isn’t hitting the headlines compared to 3D
printing, the application of the technology has brought acclaim to a number of
well-documented projects in recent months. Examples of such include the creation
of custom-machined aluminium-joint housings for a powered exoskeleton. This
project, designed and built by the University of Houston, is a key part of a new
robotics system aimed at helping paraplegics to walk again.
At Texas-based Skyven Technologies, CNC machined parts are a key feature of
an innovative, highly efficient solar panel system innovatively designed to both
generate electricity and heat water.
Another example is Sportech, product development partner to the world’s
largest power-sports vehicle makers, which utilises CNC machining to validate
the design of components used in snowmobiles, utility vehicles and motorcycles
prior to large-scale manufacturing.
The advantages of CNC machining
Where 3D printing is an additive process, building up layers to create an
object, CNC machining is effectively the opposite, cutting into
engineering-grade plastic and metal to create high-quality prototypes and
functional end-use parts.
3D printing is ideal for highly specialised, intricate and customised
designs, and its potential for an almost infinite variety of outputs makes it
perfect for iterative product development. It does, however, have economical and
physical limits regarding scale and size, making it less suitable for large
production runs.
It’s in situations such as this where CNC machining can offer an advantage.
CNC machining can be used for small batches of products, but at this level a
higher unit cost makes it more economical - and therefore more popular - for use
in the manufacture of parts for commercial and industrial equipment and
machinery.
The key benefit of the CNC machining process is its ability to produce
considerable quantities of precision-crafted parts and products in a variety of
materials, all of which will have the true properties of that particular
material, making them suitable for form, fit and function testing.
Indeed, final parts manufactured though high speed milling and turning
processes are almost indistinguishable from moulded parts. Not only does this
make for high-quality prototypes that can be used as jigs, fixtures and
one-offs, but the resultant high-quality surface finishes, free from the layer
lines often found on 3D printed parts, mean that CNC machining is an ideal
process for producing end-use parts.
Meeting increasingly tough challenges
The application of CNC machining and 3D printing needn’t be mutually
exclusive.
CNC machining can be employed as an add-on to fine tune 3D printed objects,
and doesn’t have to be used just for larger production runs. Indeed, it’s
possible to use the two processes in conjunction to meet the increasingly tough
design challenges faced by today’s manufacturers, such as the demand for ever
more lightweight components and products, and for objects with complex
geometries. In situations such as these, the flexibility of 3D printing can be
enhanced by the precision of CNC machining to ever more intricate objects.
Manufacturing businesses must embrace constantly developing technology to
meet the evolving demands of their customers. While 3D printing enjoys all the
plaudits, CNC machining is playing its part – whether in isolation or
collaboration with other processes – in creating more effective parts and
products, faster and more efficiently than ever before.