Low Volume CNC machining presents a new perspective on how one can realize high MRR in cases where the production rate is low. This is used in modern prototypes because of the effectiveness and reliability of the technique in the aspects of risk reduction, speedy delivery of products, and flexibility in changing the design. CNC low-volume manufacturing is therefore defined as the creation of a limited number of products at a time, which may be between 10 and 1000, and is appropriate for organizations that seek to reduce their manufacturing costs. In addition, it enables one to change the product designs and not incur severe losses. This article is devoted to the description of the benefits of low-volume CNC machining and some recommendations concerning the design for this process. Stick with it to find these and many more.
Low-volume CNC manufacturing is essential because of its flexibility and ability to adapt to changes. It is handy in identifying small targeted markets with specialized goods to sell without investing much money. Because of its relatively low cost, it is suitable for new businesses and small enterprises, which are the beginning of most organizations. The market is not saturated and this makes it easy for firms to enter the market and also to adapt to the trends in the market easily. It also reduces risks during the product launch since the strategies can be tested and adjusted. Also, low-volume manufacturing enables new technologies such as 3D printing and new materials such as carbon fiber to be incorporated. In addition, it enhances sustainability by cutting on the use of materials and the harm to the natural environment.
Conventional CNC machining is used to manufacture small lots of parts, often from aluminum, by applying the latest CNC technology. This method suits organizations that do not need to produce large batches of products simultaneously.
This approach is incredibly economical since tooling is not necessary. It is ideal for taking an idea from the conceptual to the prototyping stage and is a good transition to full-scale production.
Therefore, low-volume CNC machining is beneficial to companies. It reduces costs and protects the capital. It is flexible in design and easy to edit when errors have been made. It is good at handling the customers’ feedback, which improves the products. It allows one to establish a market share quickly with quality parts. This rapid entry helps in getting a competitive advantage for the organization in the global market. It improves the cash position, and it produces revenues faster. Moreover, It ensures high quality of the components with a high degree of accuracy.
In low volume CNC machining, emphasis is given to making single parts or a few of them in a batch. The primary goals are short production times and low costs. The work holding and tooling services that we provide are of superior quality to that of other regular workshops. These are used to accurately cut single pieces or a few at a time in a production line. In our approach, the key concepts of flexibility and adaptability are stressed. This also helps easily switch from one part design to another and from one volume to another. Yangsen keeps on updating our technologies for new inventions and to work more effectively. Our company aims to provide superior quality parts to fit a particular project requirement.
The selection of materials has a direct impact on the overall costs of the project, and this is why it is crucial to select the right material for both short and long runs. Another factor that should not be overlooked is machinability because different materials may differ in cost and ease of work.
In other words, when selecting a CNC machine shop, avoid using expensive and hard-to-obtain materials unless their properties are critical to the application.
When deciding on the manufacturing process, one has to define the project’s range. Some of the key factors that should be taken into consideration are market factors, product factors, and time factors. Low-volume manufacturing is most appropriate where the product has not been proven to be accepted in the market or where there is a likelihood of competitors imitating the product.
As the product cycle of innovation continues to shorten in today’s world, low-volume manufacturing is apparent. It creates a lot of value by efficiently satisfying growing market demands. Therefore, it is necessary to understand these nuances to choose the right manufacturing approach for the project’s success.
The application area of low-volume machining includes;
CNC machining is one of the most accurate and fastest techniques in manufacturing; as such, it is used in the production of surgical tools and implants. In addition, through this technology, manufacturers can develop diagnostic equipment and imaging devices, which enhances the ability to diagnose health complications. Also, due to CNC machining, components for prosthetics and many other medical equipment are produced to meet the standards of critical uses in the medical industry.
In the aerospace industry, CNC machining is applied to the production of the blades of the turbine and other difficult-to-form parts of the engine, which are vital to the safety and operation of the aircraft. It is also used in manufacturing avionic systems and structural parts to attain the precision and dependability of aerospace equipment. Therefore, CNC machining enhances the production of aerospace technology because it offers quality aerospace parts.
CNC machining is also crucial in the electronics industry, where it is applied to create complex parts and sub-assemblies of electronic gadgets. It is also applied in the manufacturing of circuit boards and semiconductor equipment to guarantee their efficiency and performance. Furthermore, its employed for the production of semiconductor manufacturing and electronics and sensors. Also, precision machining is a crucial factor when it comes to the delivery of consistent electronic parts that are used in different technologies.
CNC machining is widely used in tooling and mold making because of its significance in the manufacturing of molds, dies, and tooling parts that facilitate production. Further, it is involved in the enhancement of injection molding and die casting because of its excellent tooling services. Moreover, it assists the stamping and forming processes to be precise and accurate in the manufacturing processes. In addition, CNC machining enables one to design some of the tools for a specific industry to improve the processes in the various industries.
In industrial manufacturing, low-volume machining is vital in producing some of the equipment parts and elements used in the running of industries. Besides, it improves the production tools, which in turn helps the automotive, machinery, and consumer goods industries. In addition, low-volume CNC machining enhances the accuracy in the production of manufacturing tools and components, hence enhancing industrial production. Besides, it allows the manufacturing of quality parts that improve the productivity and efficiency of organizations in the industries.
In the case of plastic fabrication, CNC machining is vital in the production of the plastic parts and housing that are unique to the design of the product. It is also involved in the production of housings and parts of other consumer products that are associated with product function. Besides, CNC machining also helps the electronics, automobile, and medical devices industries to obtain accurately machined plastic parts. Besides, it improves the product design and performance by providing machined plastics that meet the market standards.
Let’s briefly discuss several low-volume manufacturing techniques;
Injection molding is most suitable for large volume production, but it is relatively costly. Low volume injection molding on the other hand, uses cheaper material for a small number of shots, and these are not as durable as steel molds. Low volume methods are not very suitable to increase the production volume because they involve tooling changes. In such cases, efficient methods of production like CNC milling and 3D printing are more suitable for market entry as they do not include the pre-production process.
CNC milling is a manufacturing process that is used to cut or remove material from a workpiece to produce the desired shape of a part. It is characterized by high accuracy and the capability of molding complex forms. CNC milling is suitable for producing small numbers of parts with high precision and is used in aerospace engineering, automotive, and prototyping products.
3D printing or Additive manufacturing is the process of creating objects by joining materials to make new objects by successively adding material layer upon layer based on a 3D model. It is versatile in design and can be used in prototype, small batch, and special goods production. 3D printing can use various materials, including plastics, metals, and composites, and hence it can be used in low-volume production in many industries.
Urethane casting vacuum casting or polyurethane casting is one of the molding techniques used in the manufacture of parts from urethane material. It involves pouring liquid urethane into a silicone mold and then allowing it to set. This method is applied in the making of prototypes, limited production runs, and complex shaped parts. It offers cost effective solutions with the professional finish to the products.
Rapid prototyping includes a set of technologies, including additive manufacturing, computer numerical control machining, and urethane casting. It is used where it is necessary to produce one or several items or small lots of parts with the purpose of their experimental use before mass production. Rapid prototyping is effective in that it cuts down the time it takes to complete the product since changes can be made at this stage.
Sheet metalworking is the process of manufacturing goods or components through the use of thin metal through processes such as cutting, bending and joining. It is widely employed in the production of metal components for use in industries that require strength and endurance of the parts. Sheet metal working is ideal for making special parts for low production rates that are applied in aerospace, automobile, and home appliances industries.
Vacuum casting or silicone molding is a process that is used to make parts from master patterns by using silicone molds. It is useful in the production of a small number of highly accurate components with complex shapes and smooth surface textures. Vacuum casting is applied in the mass production of the prototypes and the final parts since it is relatively cheaper.
Silicon molding or silicone molding is one of the processes that is used in manufacturing parts from silicone material. It has flexibility, wear, and heat resistance and therefore, it is used in the manufacturing of gaskets, seals, and flexible parts. Silicon molding is suitable for small-scale production of complex silicone products that are used in the medical, automobile, and electronics sectors.
|
Aspect |
3D Printing |
CNC Machining |
Injection Molding |
Urethane Casting |
Sheet Metal Fabrication |
|
Speed |
Moderate |
Fast |
Moderate |
Slow |
Moderate |
|
Material Options |
Limited |
Wide range |
Wide range |
Limited |
Limited |
|
Setup Time |
Minimal |
Moderate |
Moderate |
Minimal |
Moderate |
|
Cost-Effectiveness |
Moderate |
Moderate |
Moderate |
High |
Moderate |
|
Precision |
Moderate to High |
High |
High |
High |
High |
Comparison of Low Volume Manufacturing Methods
Do you require a partner for your low volume CNC machining requirements? Yangsen is one of the reliable manufacturers that can handle small-batch production projects.
We have state-of-the-art machining centers and experienced personnel to deliver the best in CNC Milling, Turning, 3D Printing, Sheet Metal Fabrication, and Injection Molding. Contact Yangsen today to get your low-volume projects done.
Therefore, low volume manufacturing can be defined as a situation whereby a company or a manufacturer is engaged in the production of few items or parts. This practice uses various techniques in CNC machining such as 3D printing, CNC machining, and injection molding depending on the project.
Q1. What are the techniques that are applied in low-volume manufacturing?
Low-volume manufacturing strategies include 3D printing, CNC machining, and injection molding, which are suitable for various applications.
Q2. Can CNC machining be used for high-volume production?
CNC machining is applicable in industries that demand high levels of accuracy and precision, and hence it is ideal for use in mass production.
Q3. Is additive manufacturing a better option for low-volume production?
Selective laser sintering is usually used for projects that require quick turnaround or lower accuracy. On the other hand, CNC machining is more appropriate for projects that have small tolerances or a low-quantity approach that needs more parts.
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