5 Ways to Reduce CNC Prototyping Costs

Want to slash your CNC prototyping expenses? Here's how:

1. Choose materials wisely
2. Keep designs simple
3. Use smart machining methods
4. Try split machining
5. Adjust tolerances and finishes

These tactics can cut costs by 15-80% without sacrificing quality.

Quick Comparison:

The big secret? Cut machining time. As Aaron Lichtig from Xometry says:

"The biggest cost driver is often machining time."

Let's dive into how you can save big on your next CNC project.

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What affects CNC prototyping costs

CNC prototyping costs depend on several factors. Here's what you need to know:

Machine time: This is the big one. More time = higher cost. Complex parts with tricky features? That's more machine time.

Materials: Your material choice matters. Soft metals like aluminum? Cheaper to machine. Hard stuff like titanium? That'll cost you.

Design complexity: Keep it simple to save money. Deep pockets and sharp corners? Those drive up costs.

Tolerances: Tighter tolerances = higher costs. Check out this breakdown:

Quantity: Bulk orders can lower per-unit costs. Setup costs get spread out.

Finishing: Extra processes like polishing add to the bill.

Want to cut costs? Try these:

1. Simplify designs
2. Use standard sizes
3. Avoid deep cavities
4. Round internal corners
5. Keep walls thick enough
6. Use tight tolerances only where needed

Remember: Smart design choices can save you money without sacrificing quality.

Choose materials wisely

Picking the right materials can make or break your CNC prototyping budget. Here's how to save money without compromising quality:

Know your options

CNC machines work with various materials. Common choices:

• Metals: aluminum, steel, brass, copper
• Plastics: ABS, acetal, nylon, polycarbonate

Each has its strengths and weaknesses:

Match material to function

Don't overspend. Choose based on:

• Strength requirements
• Environmental factors
• Ease of machining

If you're making a non-load-bearing part for mild conditions, plastic might do the job. No need for expensive metals.

Consider machinability

Some materials are easier to work with. This affects machine time and tool wear.

Aluminum is a top choice. It's easy to cut and gentle on tools. Steel, while stronger, takes more time and effort to machine.

Think about weight

Lighter materials can save money in two ways:

1. Less raw material used
2. Faster machining times

Aluminum and magnesium are good lightweight options.

Don't forget finishing

Some materials need extra work after machining. This adds cost. Steel might need painting to prevent rust. Aluminum often looks good right off the machine.

Pro tip: Ask your machinist. They can suggest cost-effective materials for your specific needs.

2. Keep designs simple

Simplifying your designs can slash CNC prototyping costs. Here's how:

Avoid thin walls

Thin walls are a machining nightmare. Stick to these minimums:

• Metals: 0.794 mm
• Plastics: 1.5 mm

Smart cavities

Deep cavities = longer machining time = higher costs. Remember:

• Depth should be 3-4 times the width, max
• Add fillets to internal corners (at least 1/3 of cavity depth)

Stick to standards

Standard features are faster and cheaper:

• Holes: Use common drill bit sizes
• Threads: Keep length to 2x hole diameter
• Corners: Add radii, not sharp 90-degree angles

Fewer setups

Every part repositioning ups the cost. Align main features with the six principal directions when you can.

Cut the complexity

• No curved holes (CNC can't do them)
• Skip tiny features needing special tools
• Ditch unnecessary text or logos

"Ask yourself: 'What CNC machining process would this feature need?'" - Xometry Pro

This simple question can help you spot cost-drivers in your design.

Function over form

Fancy looks often mean complex machining. Consider:

• Post-machining for cosmetic touches
• Bevels instead of rounded outer corners
• Adding a boss structure for flatness and less milling

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3. Use smart machining methods

Want to slash CNC prototyping costs? Smart machining is your secret weapon. Here's how to do it:

Optimize toolpaths

CAM software is your best friend here. It creates efficient toolpaths that cut down on unnecessary movement. The result? Shorter cycle times.

Go high-speed

High-speed machining is a game-changer. Take SolidCAM's iMachining tech - it can cut cycle times by up to 70% AND make your tools last longer. Win-win.

Multi-task your machine

Why do one thing when you can do two? Run multiple operations at once to speed things up and get the most out of your machine.

Pick the right tools

It's not just about having tools - it's about having the RIGHT tools. Choose based on your material, cutting forces, and how long the tool will last. Your wallet (and your machine) will thank you.

Fine-tune your parameters

Spindle speeds and feed rates aren't one-size-fits-all. Adjust them for each material and tool combo. It's like finding the perfect settings on your car - smoother ride, better performance.

Let data be your guide

Use monitoring systems to keep an eye on your machine's performance. It's like having a fitness tracker for your CNC machine - you'll spot issues before they become problems.

"Constant load and chip thickness is key to the success of iMachining, also with very small cutters and machining in hard or highly abrasive materials." - Dr. Emil Somekh, Founder and CEO of SolidCAM

Smart machining isn't just about working harder - it's about working SMARTER. Give these methods a shot and watch your efficiency soar.

4. Try split machining

Split machining can slash costs in CNC prototyping. It's about breaking complex parts into smaller, simpler chunks. Here's the deal:

1. Easier machining

Complex parts often need fancy tools and setups. Splitting them lets you use standard machines and tools.

2. Less material waste

Machining from one big block? Tons of waste. Splitting uses smaller pieces, saving cash on materials.

3. Faster production

Simpler parts = quicker machining. Less machine time, less labor cost.

4. Fewer errors

Complex parts are error-prone. Splitting cuts this risk, avoiding costly do-overs.

Check out this real-world example:

A company needed a complex aluminum alloy car reflector. Instead of one-piece machining, they split it up. They added screw studs to connect the parts. Result?

• 40% less machining time
• 25% lower material costs
• 50% lower error risk

But hold up. Split machining isn't always the answer. It's best for:

• Parts with deep pockets
• Designs needing multiple setups
• Prototypes not needing single-piece strength

KAD Models nails it: "The bottom line is that increased cycle time and material use result in increased cost and lead time."

So, next time you're planning a CNC prototype, ask yourself: "Can I split this?" It might save you big time.

5. Adjust tolerances and finishes

Tight tolerances and smooth finishes can skyrocket your CNC prototyping costs. Here's how to keep them in check:

Loosen those tolerances

The tighter the tolerance, the higher the cost:

Ask yourself: "Do I really need that tight tolerance?" Often, you don't.

Surface finish: Rough or smooth?

"As-milled" (125 µin roughness) is your budget-friendly option. Smoother = pricier:

Cost-cutting tips:

1. Use standard tolerances (+/- 0.005" is often fine)
2. Save high precision for critical features
3. Go "as-milled" where looks don't matter
4. Use GD&T for smarter tolerancing

Real-world example:

A company slashed prototype costs by 40% by:

• Relaxing tolerances to ±0.005" for most parts
• Keeping ±0.001" only for crucial surfaces
• Using "as-milled" finish for hidden components

Bottom line: Every decimal place in tolerance adds a zero to the price. Be smart about precision.

Conclusion

You can slash CNC prototyping costs without compromising quality. Let's recap the key money-saving tactics:

These aren't just theories. Real-world results:

A medical device maker cut prototype costs by 40% by relaxing tolerances and using "as-milled" finishes on non-critical parts.

An aerospace supplier saved 35% on material costs by switching from stainless steel to aluminum 6061 for initial prototypes.

Cost-cutting is ongoing. Keep these in mind:

1. Regularly simplify designs

2. Stay on top of new materials and machining techniques

3. Team up with your machining partner to find savings

FAQs

How to make machined parts cheaper?

Want to cut CNC machining costs? Focus on these areas:

1. Design optimization

Simple tweaks can save big bucks:

• Add radii to internal vertical edges
• Keep cavity depths shallow
• Beef up thin walls
• Stick to standard hole sizes

2. Smart material selection

Pick materials that fit your part needs and budget.

3. Tolerance tightening

Only get super precise when you HAVE to.

4. Streamline production

Cut down on setups and ditch complex features.

Here's a quick cheat sheet for cost-saving design:

Remember: Machining time is often the biggest money drain. As Aaron Lichtig from Xometry puts it:

"The secret to CNC machining cost reduction is cutting down on machining time wherever possible."

So, keep it simple and watch those costs drop!