RAYMING PCB & ASSEMBLY

What is CNC Rapid Prototype Machining and How Does it Work?

CNC rapid prototype machining can be described as a great technique

which permits businesses to be able to design as well as create very

accurate and precise product prototypes. It deals with the utilization of

computer-controlled machines to carve out product models from solid

material blocks like metal or plastic. The process aids in the identification

and rectification of any potential flaws or issues in the design of the

product before you embark on mass production.

Furthermore, CNC rapid prototype machining is cost effective especially

for small-batch manufacturing. Here, we will be explaining what rapid CNC

means and give a detailed introduction, which includes its considerations,

typical methods, benefits and pitfalls, applications, and more. Let’s begin.

Table of Contents

What is CNC Rapid Prototype Machining?

CNC rapid machining brings together two well-known terms in

manufacturing, which are rapid prototyping and CNC machining. This

deals with the creation of a prototype or physical model of a particular

product from the 3D or CAD model making use of CNC machines or

computer numerical control machines.

PCB Manufacturing & Assembly Services https://www.raypcb.com/

 RAYMING PCB & ASSEMBLY

The CNC machine helps in reading instructions from the digital file and

then goes ahead to translate them to accurate cutting tool movements. It

results in a very accurate result as well as a consistent part which meets

the right specifications.

Speaking in general terms, businesses usually work with CNC prototype

machining during the fabrication of a few parts before there is a need for

a larger batch. This prototype machining will serve different purposes,

which includes the determination of how a specific part would look when

it is completed and testing to see if it would function as it should.

Using advanced machinery and software, rapid CNC provides speed,

precision, as well as customization during the process of manufacturing. If

you desire a cost-effective and a quick prototype of the complex parts,

then the best process available is CNC rapid prototype machining.

Request PCB Manufacturing & Assembly Quote Now

How Does Rapid Prototype Machining Work?

PCB Manufacturing & Assembly Services https://www.raypcb.com/

 RAYMING PCB & ASSEMBLY

CNC Prototype

The rapid machining principle starts with the creation of the 3D

design’s CAD file. From this CAD file, a G-code is generated which the CNC

machine will be able to interpret. Also, before rapid machining, there is a

need to assess this G-code to make sure of no issues or errors. Once you

are okay with the testing results, then the part is produced.

CNC rapid prototype machining is categorized as a subtractive process.

Working with the G-code’s instructions, the machining of the parts is done

with different electronic cutters and tools. During the stage of

manufacturing, you have access to different materials. Also, after

completing the rapid machining process, that part is taken out of the

machine, which is then completed based on what you want.

Typical CNC Rapid Prototype Machining Methods

Rapid CNC machining deals with different methods, which involves the

removal of some of the parts of a specific workpiece in order to create

desired products. Let’s consider these methods.

Milling

This is a method whereby this cutting tool usually rotates. Whenever

the milling tool comes in contact with the workpiece, the chips will be

PCB Manufacturing & Assembly Services https://www.raypcb.com/

 RAYMING PCB & ASSEMBLY

taken out. Operations related to CNC milling may cover end milling,

chamfer milling, face milling, tapping, boring, drilling, etc.

Furthermore, milling is a very versatile method of fabrication with

high tolerances and precision. It is great for different materials and is also

fast. Its ability to create different intricate parts is a great benefit of milling.

Moreover, its cons include huge waste, high cost of equipment, and

requirement for different tools.

Turning

Turning signifies that a workpiece is undergoing rotation rather than that

of milling where the cutting tool rotates. This tool connects to its rotating

workpiece so as to help remove swarf or metal chips. In addition, CNC

turning is useful for manufacturing shafts. Furthermore, you can apply it

to a cylinder’s interior or exterior. You can achieve turning for great

accuracy.

Drilling

Drills are specifically designed to make holes, although milling machines

can handle this as well. However, what differentiates both methods? Drills

make use of the tip of the tool in generating a hole, whereby the milling

tools work with cutting edges found around the periphery of the cutting

head.

PCB Manufacturing & Assembly Services https://www.raypcb.com/

 RAYMING PCB & ASSEMBLY

The rapid CNC drilling machines are usually utilized in automating this

task, offering more economical solutions and greater precision.

Grinding

The CNC grinding machines help in the removal of materials through the

spinning of the grinding wheel. Its goal is offering high-precision finishes

to the metal workpiece. Also, the surface quality which you can achieve is

very high. This is why, instead of measuring the last part from the raw

materials, you can employ it as a finish process.

Types of Rapid CNC Machines

There are different CNC machines, which includes plasma cutters, routers,

lathes, and mills. Every machine type comes with its unique capabilities

and works for several applications. Furthermore, mills are utilized for

drilling, cutting, as well as shaping materials like plastic or metal.

Primarily, lathes are utilized for turning the cylindrical shapes, while the

routers are utilized for the cutting of intricate designs to sheet materials.

The plasma cutters utilize plasma torches of high temperatures for cutting

the metal through.

What are the Applications of the CNC Rapid Prototype

Machining?

PCB Manufacturing & Assembly Services https://www.raypcb.com/

 RAYMING PCB & ASSEMBLY

CNC rapid prototypes are useful in practically all industries requiring

accurate machining. Furthermore, these industries usually demand some

functional prototypes having features that are equal to final products.

Here are some of the applications of rapid CNC machining.

Medical Industry

Medical industry equipment needs hard materials and microscopic

precision. Furthermore, the industry features tight tolerance demand for

several parts like implants, safe enclosures, orthotic devices, prosthetics,

MRI machines, implant holders, surgical scissors, biopsy tubes, etc.

For this case, the process of CNC rapid machining can offer functional

prototypes with great quality and accuracy which other methods will not

be able to achieve. In addition, the medical industry enjoys a material

choice’s versatility provided by prototype machining which meets the

parts’ requirements manufactured from plastics and metal.

Automotive Industry

CNC rapid prototype machining is great for creating prototypes of

different parts in automotives. Before embarking on mass production, you

have to test the prototypes to see if they’ll function effectively and suit

properly inside a vehicle.

PCB Manufacturing & Assembly Services https://www.raypcb.com/

 RAYMING PCB & ASSEMBLY

However, the automotive industry also demands parts and gears having

very tight tolerances. Rapid machining creates prototypes that match the

intended purpose and exact specifications.

Aerospace Industry

For aerospace, several aircraft parts can experience increased wear or

drag as a result of a small error. This causes the failure of these parts

when it’s an airborne aircraft. Furthermore, CNC rapid prototype

machining helps in testing the functionality of the part before using it in an

aircraft. In addition, it offers parts having high accuracy and precision.

This industry evaluates the innovations and performance of new materials

and parts constantly through the CNC rapid prototypes. Many

components used in the aerospace industry, which includes bushings,

landing gear ports, airfoils, manifolds, etc., are produced with the help of

CNC rapid prototype machining.

Defense and Military Industry

CNC rapid prototype machining can be widely utilized in the defense

and military industry. Since the majority of military and ammunition

vehicles necessitates extremely intricate contraceptives in order to

function effectively, prototypes are highly needed. Furthermore, the

defense and military industry devices that make use of rapid machining

PCB Manufacturing & Assembly Services https://www.raypcb.com/

 RAYMING PCB & ASSEMBLY

include transportation components, plane parts, ammunition,

communication components, etc.

Energy and Oil Industry

The energy and oil industry demands components having great strength

to help in digging and extracting resources out from the extreme depths

underneath the surface of the earth. Rapid CNC helps in the creation of

these parts.

Construction and Architecture Industry

Construction and Architecture extensively makes use of CNC machining in

fabricating the exterior and interior elements. At first, this operation was

performed with the help of injection molds. This caused an increase in

expenses and time. However, with cc rapid machining prototypes, it has

become less expensive and faster.

Request PCB Manufacturing & Assembly Quote Now

What are the Benefits of CNC Rapid Prototype Machining?

PCB Manufacturing & Assembly Services https://www.raypcb.com/

 RAYMING PCB & ASSEMBLY

There are many benefits that come with CNC rapid prototype machining.

Efficient and Quick

Rapid CNC is fast and very effective for creating prototypes. CNC machines

with little supervision, these CNC machines can help transform 3D models

into real objects within hours. This less lead time ensures faster deliveries

of the finished products for the users compared to the alternative

approaches of prototyping.

High Precision and Accuracy

Regarding accuracy, this methodology surpasses other methods of

prototyping by a huge margin. It might be utilized in creating parts having

great accuracy. There may be an increase in the surface finish through the

application of sophisticated processes for finishing.

PCB Manufacturing & Assembly Services https://www.raypcb.com/

 RAYMING PCB & ASSEMBLY

This is what makes it appropriate for fabricating the parts requiring tight

tolerances for engineering and scientific applications.

Makes use of versatile materials

You may use CNC prototyping on versatile materials. As a result of

technological limitations, the majority of prototyping methods like 3D

printing are usually confined to specific materials. This CNC prototyping

can make prototypes easily making use of the material intended for the

final product.

Easily modified

There is an occasional need to make corrections to your design during the

phase of product development if you discover any problems. Using a CNC

rapid prototype, the task becomes an easy one. Just correcting the fist

CAD design as well as reprogramming your machine will be just fine. This

helps in reducing the time of the design and expedites the introduction of

the product into the market.

No fixed tooling required

Majority of prototyping usually needs special tools, which have to be

prepared beforehand. An example here are hardened dies that help in

injection molding. This could raise the production cost as well as prolong

PCB Manufacturing & Assembly Services https://www.raypcb.com/

 RAYMING PCB & ASSEMBLY

the lead time. You don’t need any of these for CNC rapid prototype

machining. This approach’s turntable has different tools. The tools may be

replaced or cycled through to finish up the task.

Repeatability and Consistency

Because CNC machines are usually computer controlled, they can

reproduce identical components repeatedly, with minimal deviation in

quality. Also, these CNC machines help in producing successive batches

with small dimensional variations. This is why they are very suitable for

any manufacturing assembly requiring very tight tolerances present

between the mating components.

What are the Cons of the CNC Rapid Prototype Machining

There are several reasons why the use of rapid machining is great for

making prototypes. However, there are some limitations that may make

the process an inappropriate one for some projects. Now, let’s consider

them.

It is more expensive compared to 3D printing

The creation of prototypes using CNC Machining is usually more expensive

compared to other technologies such as 3D printing. As a result of running

the large CNC machines as well as the extra trained labor needed, CNC

PCB Manufacturing & Assembly Services https://www.raypcb.com/

 RAYMING PCB & ASSEMBLY

prototypes are usually more expensive. However, the raw materials, which

includes the metals are much more expensive than the 3D printing

Much material waste

CNC Machining can be described as a form of subtractive manufacturing.

It means that the creation of the prototype is through the progressive

reduction of excess material out of a block till the eventual product is

revealed. This generates much waste, which affects the environment

negatively and therefore increases the production cost.

Geometrical Constraints

The modern rapid CNC machines of today like 5-axis milling machines

come very sophisticated that could shape or cut any complicated parts.

Moreover, these machines might find some of these designs challenging.

Skilled and Technical Labor

The creation of the CAM and CAD file requires technical knowledge. In

addition, setting up as well as running the CNC machine requires great

skill. Expertise in the rapid CNC prototyping procedure for innovative ways,

testing, experience, as well as a creative vision is necessary. In general,

CNC machining operators have to be experienced and properly trained.

Conclusion

PCB Manufacturing & Assembly Services https://www.raypcb.com/

 RAYMING PCB & ASSEMBLY

CNC rapid prototype machining is a great option when you want to

produce prototypes and metal parts with better structural integrity as well

as great mechanical properties. On the contrary, 3D printing is well

adapted to the manufacturing prototypes so as to visualize the concepts

even in little quantities.

Related Posts:

1. What is the Significance and Applications of Rapid PCB Prototype?

2. Top 10 SMT Manufacturers In 2023

3. What are PCB Pins and How Do They Work?

4. How Does a Relay Work

https://www.raypcb.com/cnc-rapid-prototype/

PCB Manufacturing & Assembly Services https://www.raypcb.com/