Learn the power of computer-controlled machines to bring your ideas to life.
computer-numeric-controlled (CNC) machines. CNC machines provide incredible opportunities to turn imagination into reality. Using computer controlled tools in creative ways allows us to leveraging technology to express new ideas and develop problem solving skills.
True mastery lies in understanding the process and continuously learning through experiences.
We emphasize the importance of understanding the underlying principles and processes involved in computer-controlled machining. This approach allows us to take a deeper dive into how the machine works, the materials used, and the parameters that affect the design & quality of the final piece.
Reductive and additive machining.
Both reductive machining and additive machining have their unique strengths and applications. The choice between the two methods depends on factors such as the desired object's complexity, material properties, production volume, design requirements, and cost considerations.
Reductive Machining:
Reductive machining, also known as subtractive manufacturing, involves removing material from a larger block or work piece to shape it into the desired object. This process typically involves cutting, drilling, milling, or grinding the material using tools such as lathes, mills, or routers. The material is gradually reduced or removed until the final shape is achieved. Traditional methods like carving or sculpting by hand can also be considered reductive machining.
Additive Machining:
Additive machining, also known as additive manufacturing or 3D printing, is a process where objects are built layer by layer using a computer-controlled machine. Instead of starting with a larger block of material and removing parts, additive machining adds material, usually in the form of liquid resin, powder, or filament, to gradually build the object. The machine follows precise instructions from a computer model to deposit and solidify or fuse the material in specific locations, layer by layer, until the final object is complete.
What are the criteria for choosing between additive and subtractive machining ?
Design Complexity: Additive machining excels in creating complex geometries, intricate internal structures, and customized designs. If the project requires intricate or organic shapes that are difficult or impossible to achieve through traditional subtractive methods, additive machining may be the better choice.
Material Selection: Consider the material properties needed for the project. Additive machining has a range of materials available, including plastics, metals, ceramics, and composites. However, if the project requires specific materials that are not compatible with additive manufacturing processes, subtractive machining may be more suitable.
Production Volume: Production volume plays a significant role in the decision-making process. Additive machining is well-suited for low to medium production volumes, prototyping, and small-batch production. Subtractive machining is generally more efficient and cost-effective for larger production runs or high-volume manufacturing.
Time Constraints: Consider the project timeline and time-to-market requirements. Additive machining can offer faster lead times for prototyping and small production runs, as it eliminates the need for tooling and setup associated with subtractive methods. Subtractive machining may be faster for larger production volumes due to the simultaneous machining of multiple parts.
Cost Considerations: Evaluate the overall cost of the project, including material costs, equipment expenses, and labor. Additive machining can be cost-effective for small production runs or highly customized designs that would be expensive to produce with traditional tooling. Subtractive machining may be more cost-effective for larger production volumes, as the cost per unit can be lower due to economies of scale.
Surface Finish and Tolerance Requirements: Consider the required surface finish, dimensional accuracy, and tolerances for the project. Subtractive machining generally offers higher precision and better surface finish compared to additive machining. If the project requires tight tolerances or superior surface quality, subtractive machining may be preferable.
Sustainability and Environmental Impact: Evaluate the sustainability and environmental impact of each process. Additive machining can minimize material waste as it only uses the necessary amount of material, while subtractive machining generates more waste due to material removal. Consider the environmental implications and sustainability goals of the project.
It's essential to assess these criteria and weigh the pros and cons of each approach based on the specific project requirements to determine the most suitable machining process, whether it be additive or subtractive. Additionally, consulting with experts or conducting a feasibility study can provide valuable insights for making an informed decision.
Additive Manufacturing Cost Factors:
Material Cost: Calculate the cost of the material used in the 3D printing process, such as filament, resin, or powder.
Machine Time: Estimate the time taken by the 3D printer to build the object layer by layer. Machine time is typically calculated based on the machine's hourly rate or the time taken to print a specific volume of material.
Labor Cost: Consider the labor hours required for tasks such as file preparation, machine setup, post-processing, and finishing.
Equipment and Maintenance: Account for the initial investment and ongoing maintenance costs of the 3D printing equipment, including the printer itself and any necessary peripherals.
Design Complexity: More complex designs may require additional supports, increased print time, or specialized processes, which can impact the cost.
Post-Processing: Some 3D printed parts may require post-processing steps, such as support removal, sanding, or surface treatment, which can contribute to the overall cost.
Reductive Manufacturing Cost Factors:
Material Cost: Determine the cost of the raw material required for machining, such as the cost of metal or wood stock.
Machine Time: Estimate the machining time needed to remove material and shape the object. Machine time is typically calculated based on the machine's hourly rate or the time taken to complete specific operations.
Labor Cost: Consider the labor hours required for tasks such as programming, setup, tool changes, monitoring, and inspection.
Tooling and Tool Life: Account for the cost of tooling, such as cutting tools or drills, and the expected tool life before replacement.
Material Waste: Consider the amount of material waste generated during the machining process, as it contributes to material costs and disposal expenses.
Post-Processing: Some subtractive manufacturing parts may require additional post-processing steps, such as deburring, polishing, or coating, which should be factored into the cost.
It's important to note that these factors are general considerations, and the specific cost estimation for additive or subtractive manufacturing should be based on project-specific details, such as part complexity, volume, labor rates, material prices, and overhead costs. Consultation with experts or performing a detailed cost analysis based on specific manufacturing parameters will provide more accurate cost estimations for your project.