Fabrication from sheet metal is the best method for producing long-lasting parts, whether they are one-of-a-kind prototypes or production supports for mass quantities. The production of components using this method also has a low overall cost. When compared to other machining processes, however, considering the fact that sheet metal parts are made CNC metal machining from a single flat plate is an additional design consideration that needs to be taken into account. In order to help you save both time and money on your next project, here are five tips that you can use.


1. Make sure you use the appropriate material
One of the most important factors that determines the cost of a part is its material cost.Be sure to use the stock size, and choose the material you're working with with care.If you are prototyping, you might want to think about using aluminum 5052 with 304 stainless steel or other materials that are less expensive.


2. Develop standardized design criteria
When designing your part, make sure to use the standard gauges for sheet metal. The thickness of a sheet metal part is primarily determined by the geometry of the part; however, thicker metal may limit the amount of bending that can be achieved with your part.


3. Make your folds less complicated.
In general, the cost of the component will be higher if it has a higher degree of complexity.Create a straightforward elbow with a radius that is equal to the sheet thickness in order to cut costs.When it comes to accuracy, small bends on large, thick parts are problematic and should be avoided whenever it's possible to do so.


4. Reduce the amount of use of extremely close tolerances
Frequently, there are only a few characteristics of a part that are essential to its function.The cost of producing a component will increase proportionately with the number of features that require tolerancing in the design.It is essential to assign tolerances to only the mission-critical features and surfaces in order to avoid incurring costs that are not necessary.


5. Keep the bending in the same direction consistently.
To avoid having to reorient parts and save time and money, bends in the same plane should be designed to go in the same direction.The cost-effectiveness of the part will also be improved if the bend radius is maintained consistently.


When Designing Machined Parts, It's Important to Avoid These 5 Mistakes


When Designing Machined Parts, It's Important to Avoid These 5 Mistakes.


Your part will be milled or machined on one of our CNC machines within a day after you upload the CAD model to our automated quoting and design analysis engine. However, despite all of the technological advancements that make it feasible, the human component is still very important and is frequently to blame for the reoccurring issues that we find in CNC machined parts. If you can avoid making these five common mistakes, your designs will likely improve, Precision Machining Services your run times will be cut down, and your final manufacturing costs may be reduced.


1. Stay away from functions that require additional processing that isn't necessary
It is a common oversight to design a part that does not need to be cut by machine. This unnecessary machining adds to the run time of the part, which is one of the primary factors that determines the final production cost.Take the following illustration as an example: the design specifies the critical circular geometry that is required for the application of the part.It requires that the middle of the product have a square hole or feature machined into it, and then the surrounding material must be cut away to reveal the finished product.However, in order to process the remaining material using this method, a significant amount of additional run time is required.In a design that is more straightforward, the machine simply cuts the part out of the block, doing away with the requirement for additional, inefficient machining of excess material.The modification to the machine's design, which we just looked at, cut the time it took by nearly half.Maintaining simplicity in the design will help you avoid extra run time, needless tooling, and additional costs..


2. Stay away from text that is raised or very small
It is possible that your component will call for a machined part number, description, or company logo.Or perhaps you think that particular text looks really cool in a particular section.However, the price will increase if you add text.Because of this, the very small end mills that are required to cut the text run at relatively slow speeds, which adds to the amount of time needed to complete the task and, consequently, the overall cost.On the other hand, if your component can accommodate larger text, cutting larger text will be a significant amount quicker, which will result in cost savings.If you have the option, go with recessed lettering rather than raised lettering. Raised lettering requires material to be ground away in order to create the letters or numbers on the part.


3. Stay away injection molding manufacturers from high, slender walls.
Wall features on part design are frequently challenging, and the cutters that are used in CNC machines are made of hard and rigid materials such as tungsten carbide and high-speed steel.In spite of this, the machining forces cause the tool, as well as the material being cut, to undergo some degree of deflection or bending.This can result in problems such as unwelcome corrugated surfaces and difficulty meeting part tolerances, both of which can be problematic.Walls are also susceptible to chipping, bending, and breaking.


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Walls with a thickness of 0. 508 millimeters or less are prone to fracture during processing and may subsequently bend or warp as a result. This is because the thickness required to increase the stiffness of the material is directly proportional to the height of the wall. Because the cutter rotates at between 10,000 and 15,000 rpm, you should make an effort to avoid designing walls that are too thick. A wall should have an aspect ratio of 3:1 as a rule of thumb. It is possible to facilitate easier machining and reduce the amount of material left over by giving the walls a draft of one, two, or three degrees so that they taper rather than stand vertically.


4. Stay away from extra features Nylon CNC Machining that you might not even use.
In order to lessen the component's overall weight or make room for additional components, certain parts have been designed with square corners or small recesses on the inside corners.The internal 90-degree angles and the small grooves, on the other hand, are not suitable for our large knives.In order to make these, it was necessary to pick up corner material using ever-more-delicate instruments.Because of this, it's possible that you'll need anywhere from six to eight different knives.Run time is increased as a result of each of these tool changes; to circumvent this, you must first determine the significance of the grooves.If the only reason for having them is to save weight, you should reconsider your design so that you don't end up paying for machine material that doesn't need to be cut.


5. Reconsider the completed form of the machined component.
Before purchasing a mold, it is common practice for the design of an injection-molded component to be uploaded to the prototyping section of our tooling service.However, the design requirements for each process are unique, and the outcomes can be quite variable.When molded, thick machined features may exhibit a variety of issues, including sinking, warping, porosity, and others.The machining process for a well-designed molded part that includes ribs, grooves, and other features takes a significant amount of time.