Manufacturing industries and workshops are always in need of efficient solutions that can effortlessly cut and shape materials and workpieces with complete automation.
With the increase in technology, multiple advanced machines have been introduced into the manufacturing industries to produce components without compromising on quality and accuracy.
In this entire process of manufacturing, some important machining methods are used to cut, shape, and manufacture new material. Today we will discuss 2 of them: CNC Machining and Injection Molding.
Not only we will discuss what these methods are, but we will also delve into their applications, pros, cons, and major key differences.
Ready for the comparison? CNC Machining vs Injection Molding, let's see which method stands out.
CNC Machining is nothing but an advanced process that automates the whole machining in the industries with the help of pre-programmed software.
Those pre-programmed software are more than enough to handle all the machining tools that perform the cutting, grinding, and all kinds of shaping and designing tasks. This whole automation results in less need for human assistance thus eliminating the chances of human error.
No matter if the material is metal, plastic or any composites, Computer Numerical Control Machining involves the cutting and carving of those workpieces to transform them into fresh functional objects without any compromise on accuracy and precision.
Unlike rigid machining procedures, CNC Machining is quite flexible in terms of producing objects on both smaller and larger scales. That's why CNC Machining is pointed as a Versatile procedure of manufacturing objects, never mind, custom-made, on a larger level or for small production units.
In non-technical words, CNC Machining is just like baking a cake, the same recipe, but can adjust the size, design, and flavor as per the need, preference, and occasion.
Same goes for CNC machines, you can manufacture multiple types of objects with simple to complex designs without doing much manual adjustments.
Prototyping is a common way to manufacture an efficient end product. Guess what? CNC Machining appreciates the process of making a prototype to finalize and inspect the design.
Once the finalization is done, CNC Machining will take charge and will ensure low-massive level production with no manual repetitive or time-consuming setups.
CNC Machining not only earned the title of Versatility but is also quite famous for being so precise. How much precision does it promise? If we were to give an example from real life, we would say CNC Machining provides more precision than cutting paper exactly on a drawn line. No exaggeration at all.
With the CNC Machining process, one can manufacture parts with tolerances up to ±0.001 inches. You can already imagine how precise and accurate those designs and cuts will be. This precision and accuracy is crucial for industries such as:
● Aerospace
● Medical
Both of these industries demand attention to detail and can't entertain any kind of error in the design or structure. Take surgical tools for example. Those tools need to be manufactured with ultimate precision. This is where the CNC Machining process comes in.
A machining process can be declared efficient only if it is capable of working with different materials offering the same quality and precision, this is why CNC Machining has earned that declaration of being ultra-diversified.
No matter whether your industry is dealing with nylon-made products or aluminum, CNC Machining can efficiently handle them without compromising on quality. Not just aluminum or nylon but it can efficiently cut and design multiple other materials including steel and polycarbonate.
So there's no such limitation to using materials when it comes to manufacturing under the CNC Machining process. The manufacturing process with CNC Machining is as smooth as it sounds while ensuring 100% diversity, endurance, and durability.
CNC Machining no doubt has immense benefits especially when it comes to ensuring quality, precision, and accuracy but as per the price factor, it might be a big NO for your industry.
Especially if your industry is at a smaller level, CNC Machining might not be a beneficial option for you. It costs way more than one can expect, from a few thousand dollars to even hundreds of thousands.
It's just the cost estimation of machines, the pre-programmed software required for efficient operation is separate. We don't deny the fact that CNC Machining embraces automation, still, a skilled human workforce will be needed.
So combining all the required machinery and skilled individuals will cost a lot.
CNC Machining involves cutting, shaping, and designing a material from start to end. In the end, a pure product will be manufactured, but what about all the remaining material? As that remaining material will be cut down during the manufacturing process, it will be of no use. A huge waste of material, no?
For example, if you use high-grade steel to manufacture a product using CNC Machining, there will be two cases; good and bad. The good part: your product will be manufactured with ultimate precision, but the bad part is that the remaining high-grade steel will be wasted in the whole process.
You'll have to invest time and energy to dispose of and recycle that wasted material. If disposed of the material irresponsibly, it will impact nature in a very threatening way.
Injection molding is an effective manufacturing method to turn melted materials into a desired form. In the real-life world, we can't find any better example than a cookie cutter. The only difference is that, instead of cookie dough you're using melted material.
The most used melted material in Injection molding is plastic, but other materials are also used in this machining procedure.
The process revolves around the shaping of melted material via Injection molding and then removing the mold once the product is ready and cold.
Examples of products made by this machining method include both small and large products such as bottle caps to automobile parts.
Injection Molding really helps when you have to manufacture the same type of products with consistency without compromising on the quality.
Injection Molding works efficiently especially when you've to manufacture the same type of products on a larger scale. And the automation this machining procedure provides is unmatchable.
You make a mold and inject the melted material in it then your desired product will be ready in the scheduled time without needing manual human effort. This is why big plastic companies utilize this method to produce similar products at a larger level.
Plastic is most commonly used in the injection molding process to create and manufacture different objects with desired shapes, but there's no limit to material use. One can use rubber, metal, or any other type of material to manufacture different kinds of products with this machining method.
This makes the Injection Molding process very flexible for those industry experts who intend to manufacture products by using different types of materials.
For example: we all see gaskets and seals that are accurately manufactured with great precision using the Injection Molding method.
But on the other hand, we also see those hard plastic-made car dashboards, which are also manufactured under the same Injection Molding procedure. This shows the level of diversification this machining method provides.
One of the notable and most beneficial things about injection molding is that it doesn't lose accuracy in the manufacturing process no matter how many times you try producing identical structures and products.
For industries that can't compromise on precision while manufacturing products at a massive level, Injection molding is the top solution. Injection molding ensures tight tolerances are considered and fulfilled religiously while designing and manufacturing the products so that everything is as per the required measurement.
No matter how similar the product dimensions are required, Injection Molding will make it possible without compromising on the standard.
Injection Molding seems like a very cost-effective option as compared to the other machining processes, but one must have to bear the initial high costs.
You might have to invest a lot in the creation of the desired shape mold. The more complex the design will be, the more expense you'll have to bear.
Unlike usual molds, the ones used in Injection Molding are made up of high-quality durable material to ensure longevity. That material usually includes steel or aluminum depending on the product that will be derived using the mold. So the process of creating that mold will require a proper setup and equipment along with skilled human assistance to design it precisely.
So, due to the initial high cost, this machining process is highly recommended for large-scale product units, as they will not get bothered by the initial investment in the mold. But for those manufacturing products at a smaller scale, following this machining procedure won't be a good idea.
You can’t expect your manufactured mold to change its design once it is completely ready to use. It's either you made a new one from scratch as per your preferred design in mind or you change the premade one by remaking it.
Both processes involve huge investments of money and time, as mold-making is not even close to cost-effectiveness while requiring months of time to be manufactured.
| Feature/Element | CNC Machining | Injection Molding |
| Machining Procedure | CNC Machining is all about the subtraction and cutting of material to convert it into | Injection Molding involves the addition of material into the mold in the form of a |
| a product. | molten state and then conversion into a preferred shape. | |
| Money Investment | CNC Machining doesn't require much initial cost, but the per-unit price is very high, going above the affordability criteria. | Injection Molding involves high initial costs to design the mold into a specific shape, but as for the per-unit cost, you won't have to worry about anything as you'll find it very cost-effective for mass production. |
| Material Allowance | CNC Machining is welcoming to all kinds of materials including metals, various kinds of plastics, and composites. | Injection Molding, although promises the production of all kinds of materials, is used mainly for plastic products manufacturing. |
| Production Level | CNC Machining is suitable for industries with low-medium production volume. It is not suitable for consistent production at the Mass level. | Injection Molding is known for its efficient production at Mass level, endorsing high-volume production with complete automation and ease. |
| Prototyping | Very easy, Quick yet reliable and appreciates diversity in the shape or design. | Not cost-effective, and also requires a lot of time and effort because mold has to be changed in terms of shape. |
| Accuracy and Fidelity | Promises high fidelity and precision as the tolerance is up to ±0.001 inches. | Ensures 100% precision and accuracy while being very consistent in terms of identical production, but doesn't promise the same fidelity and accurateness levels as CNC Machining does. |
CNC Machining vs Injection Molding: which one is the best?
Both machines hold their own significance in the world of manufacturing.
While having different pros and cons, there's one thing common in both machines is that they offer 100% accuracy. So it depends totally on your needs whether you want a machine for low-medium-level subtractive manufacturing or for massive-level additive manufacturing.
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