How to Reduce CNC Machining Expenses？

In computer numerical control (CNC) machining, whether building a single prototype or launching large-scale production, reducing manufacturing costs is always a core focus. Fortunately, with smart design decisions, costs can be cut effectively. By following a set of design for machining (DFM) principles, you can create parts that are both functional and cost-effective.

This article aims to provide you with a series of optimization design tips to help you reduce costs. First, we’ll dive into the key factors that contribute to rising CNC machining expenses. We’ll then lay out a comprehensive set of guidelines and share practical design tips designed to save you money on your project.

How much does CNC machining Expenses?

This mainly depends on the following key factors:

1. First of all, the machining cycle is one of the important factors that determine the cost of CNC machining. The longer a part takes to machine, the higher the cost will naturally be. In mass production, where processing time becomes a major cost driver, even minor design errors can adversely affect economies of scale.
2. Secondly, startup cost is also a factor that cannot be ignored. This mainly involves the preparation of computer-aided design (CAD) files and process planning. Start-up costs are relatively high for low-volume production, but it’s worth noting that these costs are fixed. If design and surface treatment technology can be flexibly adapted to cost changes, then economies of scale principles can be exploited to reduce unit expenses.
3. In addition, other production costs will also have an impact on the total cost of CNC machining. For example, meeting tight tolerance standards or producing difficult-to-machine components, such as thin-walled parts, may require the use of special tooling, enhanced quality management, and more production steps at slower processing speeds. These factors increase the overall time and expense of manufacturing.
4. Finally, material cost is also an important component of the total cost of CNC machining. The cost of bulk materials and how easily the materials are processed can have a significant impact on the overall cost. By optimizing design and carefully selecting materials, we can effectively reduce the cost of CNC machining.

How to Reduce CNC Machining Expenses?

The key to reducing CNC machining expenses is to adopt the following strategies:

1. Optimize design plan

The CAM blueprint is the starting point for product design, which is then converted into a CAD design and uploaded to the CNC machine to guide cutting. Through optimized design, CNC machine tools can complete product manufacturing in the shortest path and with the least material consumption, thereby achieving effective use of time and raw materials. Inaccurate CAD drawings can lead to high production costs as remanufacturing may be required. Consulting with experienced professionals during the design phase may increase initial costs, but will result in significant savings in the long term, especially for high-volume production. Therefore, it is recommended to invest more in design to reduce long-term CNC machining costs.

2. Simplify design to cut Expenses

Design complexity is directly related to CNC machining costs. Complex designs often require multi-axis CNC milling machines, significantly increasing overall costs. However, most complex designs can be assembled by breaking them down into simpler designs and machining them on a three-axis CNC mill. This method can significantly reduce CNC machining expenses.

3. Use rounded corner design to improve efficiency

CNC engraving machines are less efficient when handling sharp corners and 90-degree angles because they require frequent stops and turns. In order to improve processing efficiency, it is recommended to adopt a rounded corner design to enable the CNC machine tool to operate continuously and reduce pauses.

4. Set the thread length reasonably

Some manufacturers prefer to machine screws and bolts with long threads for added strength, but in most cases, short threads will suffice. Increasing thread length not only extends processing time and increases material costs, but also causes a waste of resources. Therefore, the thread length should be controlled within a range that meets the strength requirements.

5. Adjust tolerances to reduce Expenses

Tolerances represent the dimensional differences between the actual manufactured part and the design specifications, usually measured in tiny inches. When tolerances are set too tight, it drives up the overall cost given the complexity and specific needs of the part. Tight tolerances slow down processing and require the use of higher-standard CNC equipment. This not only means an increase in equipment investment, but also increases labor costs due to extended processing time. Therefore, when conditions permit, moderately relaxing the tolerance range is a wise choice, which can improve CNC machining efficiency and reduce costs. The tolerance accuracy provided by LS can reach +/- 0.005 mm, depending on customer needs.

6. Increase production to reduce Expenses

Increasing output is one of the most direct and effective ways to reduce CNC machining expenses. As production volume increases, fixed costs are spread over more parts, lowering the manufacturing cost of each part. Additionally, mass production reduces design costs because the same design blueprint can be used for mass production, further reducing tooling costs.

7. Avoid deep cavity machining challenges

Deep cavity machining involves long strokes of the tool inside the workpiece, which when implemented on a CNC milling machine can cause tool damage, rapid wear, vibration, bending, wall chatter, coolant supply problems and chip disposal problems. Not only do these issues require frequent tool changes, they also increase the risk of damage to the workpiece, which can have a significant impact on overall costs. Therefore, avoiding unnecessary cost growth is an effective strategy to save expenses.

8. Reduce over-processing

When a product requires a high post-processing finish, the processing time of CNC machine tools will increase significantly in pursuit of high quality edges. This increases machine and labor costs and accelerates tool wear. Therefore, it is crucial to reduce unnecessary over-processing. While some products may require secondary finishing to improve quality, this undoubtedly increases expenses. Directly using CNC processed products as finished products is a cost-effective option. Of course, special processes such as heat treatment, special coatings, anodizing and surface finishing are necessary in some cases, but their necessity should be carefully evaluated before implementation.

9. Avoid processing thin-walled parts

Thin-walled parts are extremely susceptible to damage during CNC machining and require special care. To avoid breakage due to processing forces or vibration, CNC machines need to cut at low speeds, which adds time and cost. Although using thicker walls instead of thin walls may slightly increase material costs, it can significantly reduce CNC machining expenses.

10. Choose a reputable manufacturer

There are many CNC machining companies, but the quality varies. Quality manufacturers may not offer the lowest prices, but they offer the best value for money and results. Some manufacturers attract customers with low prices but sacrifice operational quality. To avoid such situations, it is recommended to look for a reliable manufacturer that offers the required quality and price.

How to reduce machining time?

Reducing machining time is a key link for enterprises to improve production efficiency and reduce expenses. Here are some strategies for reducing CNC machining time:

Strategies	Description
Optimize machining procedures	By improving CNC machining procedures, unnecessary movements and pauses are reduced and machining efficiency is improved.
Use efficient tools	Choosing tools suitable for machining materials and processes can increase cutting speed and machining quality, thus reducing machining time.
Improve machine tool performance	Using advanced CNC machine tools with higher machining accuracy and speed, tasks can be completed faster.
Reasonably arrange the machining sequence	According to the structure and processing requirements of the parts, reasonably arrange the machining sequence, which can reduce repeated processing and waiting time.
Parallel machining	When possible, use parallel machining technology to process multiple parts or features at the same time to improve overall processing efficiency.
Monitor and adjust the machining process	Monitor the machining process in real time, detect and solve problems in time, and avoid machining interruptions and rework, thus saving time.
Train employees	Improve the skill level of operators and programmers so they can operate machine tools and write programs more proficiently, reducing machining time and error rates

 Is CNC Machining Cost-Effective?

It Depends on the Application: CNC machining can be cost-effective for high-precision, low-to-medium volume parts, as well as parts that require complex geometries. However, for larger production runs or parts that can be produced using other methods like injection molding, the cost of CNC machining might not be the most economical.

Precision vs. Production Volume: While CNC machining is ideal for precision and versatility, if you’re producing large quantities of parts, the cost of CNC machining may be higher compared to other manufacturing methods. For small batch sizes, CNC machining is often cost-effective because of low setup costs.

How can LS company reduce the cost of CNC machining?

LS company as a professional CNC machining service provider, with years of industry experience and technical accumulation, successfully explored a set of effective methods to reduce the cost of CNC machining.

• Optimization design and process: LS company has a professional design team, which can optimize the design of parts according to the actual needs of customers, and reduce unnecessary material use and processing steps. At the same time, the company also adopts the advanced processing technology and tool path planning, improve the processing efficiency, reduce the tool wear, so as to effectively control the processing cost.
• Improve equipment utilization: LS company pays attention to the maintenance and maintenance of equipment to ensure that CNC machine tools are always in the best working condition. Through the reasonable arrangement of the production plan, the company can make full use of the equipment resources, reduce the vacancy time, improve the utilization rate of the equipment, so as to reduce the processing cost of the unit product.
• Procurement strategy and cost control: LS company has established a long-term cooperation relationship with a number of high-quality suppliers, and can obtain more favorable prices of raw materials and tool consumables. At the same time, the company also through batch procurement and inventory management, further reduce procurement costs and improve profit margins.
• Introduction of automation technology: LS company actively introduces automatic processing system and intelligent monitoring technology to realize the automation and intelligence of the processing process. This not only improves processing efficiency, reduces labor costs, but also reduces human error and improves product quality.

Case study: LS company helps a company reduce CNC machining costs

Take an auto parts manufacturing company as an example. The company originally used traditional CNC machining methods, and the processing costs remained high, which seriously affected the company’s profit margins. After cooperating with LS Company, LS Company optimized the design of its parts according to the actual needs of the company, and adopted advanced processing technology and tool path planning. At the same time, LS Company also provides efficient equipment utilization solutions and automated machining solutions. After the implementation of a series of optimization measures, the company’s CNC machining costs have been successfully reduced by more than 30%, greatly increasing profit margins.

Conclusion

To reduce CNC machining expenses, focus on simplifying your designs, optimizing material usage, and selecting the right machines. Consider production volume to reduce unit costs and work with reliable suppliers to negotiate better deals. By being mindful of these factors, you can effectively reduce CNC machining costs without compromising on quality.

Contact us now to get exclusive customized CNC machining solutions!

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Email: info@longshengmfg.com
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Disclaimer

The content appearing on this webpage is for informational purposes only. LS makes no representation or warranty of any kind, be it expressed or implied, as to the accuracy, completeness, or validity of the information. Any performance parameters, geometric tolerances, specific design features, quality and types of materials, or processes should not be inferred to represent what will be delivered by third-party suppliers or manufacturers through LS ’s network. Buyers seeking quotes for parts are responsible for defining the specific requirements for those parts. Please contact to our for more information.

Team LS

This article was written by various LongSheng contributors. LS is a leading resource on manufacturing with CNC machining, sheet metal fabrication, 3D printing, injection molding,metal stamping and more.

FAQs

How to reduce CNC machining expenses through optimized design?

Optimizing design is the key to reducing CNC machining expenses. Simplifying product structure and avoiding unnecessary complex features can reduce machining time and material consumption. In addition, rational selection of materials, such as using easy-to-cut aluminum alloys instead of stainless steel, can also significantly reduce tool wear and machining expenses.

How does batch machining affect CNC machining expenses?

Batch machining is an effective way to reduce unit product costs. As the number of machining increases, the fixed costs allocated to each part (such as equipment depreciation, tool preparation, etc.) will gradually decrease. Therefore, rationally planning production batches and making full use of the processing capabilities of CNC equipment can help reduce overall processing costs.
Improving processing efficiency is a direct way to reduce CNC machining costs. This includes optimizing tool paths, selecting appropriate cutting parameters, regular maintenance and upkeep of equipment to ensure it is working at its best, and more. In addition, the introduction of advanced CAM software and technology, such as super string finishing technology, can further improve processing efficiency and quality.

What is the role of automation equipment in reducing the CNC machining expenses?

Automation equipment, such as automatic loading and unloading devices, intelligent monitoring system, can significantly reduce manual intervention and improve the stability and efficiency of the processing process. Although the initial investment may be high, but in the long run, automation equipment can significantly reduce labor costs, reduce errors and rework, thus effectively reducing the cost of CNC machining.

How to reduce the CNC machining expenses through a reasonable procurement strategy?

A rational procurement strategy includes long-term partnerships with suppliers, bulk procurement of raw materials and tool consumables for price concessions, and regular evaluation and adjustment of procurement lists to adapt to market changes. In addition, paying attention to the development of new materials and new technologies, timely introduction of more cost-effective alternatives, is also an effective way to reduce the cost of CNC machining .
What is the importance of staff training in reducing CNC machining expenses?
Staff training is essential to improve operational skills, reduce errors and rework time. Through regular training and skill improvement plan, employees can better master the operation and maintenance knowledge of CNC equipment, so as to improve the machining efficiency and product quality, and indirectly reduce the cost of CNC machining.