Rapid prototyping is the process of creating a physical model of a new product design as quickly and economically as possible. Some prototypes are used simply as cosmetic mock-ups or scale models, while others must meet more demanding performance criteria. Prototypes are used for testing, design iteration and to improve overall performance through incremental refinement. For these reasons, speed, flexibility and scalability in manufacturing are key attributes to look for.
Using CNC machining to produce rapid prototypes can be an ideal solution for product development. Here are the top 7 advantages to consider for your next project.
1. Speed
Speed refers not only to the actual production time, but also to all the preparatory steps that precede it, including programming and material set-up. In all cases, digital manufacturing is one of the fastest ways to go from a product design to a finished or semi-finished part.
CAD files can be converted into digital cutting files in a matter of hours, while the actual cutting time can be measured in minutes. The resulting part is then ready for gauging, finishing (painting, sanding or other secondary operations) and shipping. Injection moulding may be faster on a per-part basis, but there is a much longer set-up time to make and approve the mould tooling.
2. Choice
CNC milling and turning works on almost any solid material, including hard plastics, stainless and mild steels, brass, nickel, aluminium, magnesium and many more. With thousands of commercially available materials to choose from, it’s easy to find one that meets your application requirements.
And for prototypes, it’s possible to start with a cheaper and easier-to-machine variant, such as 6061 aluminium, while you optimise your design. Only when the design is perfected can you move to the final material, such as a more expensive stainless steel. This is another way to save development costs.
3. Economic efficiency
This means there’s no need to build moulds, dies or other complex fixtures. Of course, for high-volume production, such as die-casting or plastic injection moulding, special tools and moulds are required. But for a few hundred or even a thousand parts, it may make more sense and be more economical to opt for CNC machining instead.
By avoiding unnecessary costs, product developers can focus their resources on design improvements, testing and certification.
4. Accuracy
Digital manufacturing using modern CNC machine tools allows manufacturers to easily dial in tolerances of a few microns, or thousandths of an inch, at the touch of a button.
For a product developer, this means that prototypes with full production quality accuracy and repeatability can be produced quickly. Then, using the same accuracy, it’s easy to make further refinements to a part’s dimensions by simply tweaking the digital programme.
5. Flexibility
Need one part? Five? A hundred? CNC machining is volume indifferent, so it is just as effective to produce one part as it is to produce a hundred.
This advantage is perfect for designers who are launching a new product and are unsure of consumer response. But it’s also relevant for non-consumer industrial products, which may have fluctuating and unpredictable demand cycles and therefore benefit from the scalability inherent in digital manufacturing. This can also help developers avoid carrying unwanted inventory for stock items that could otherwise be made on-demand.
6. Versatility
Versatility means that a machine can be pre-loaded with a variety of cutting tools mounted on a rotating carousel. Multiple tools can then be called up as required to machine tapped and threaded holes, complex curves, flat surfaces, precise angles and other geometric features – all without the need to remove the workpiece and move it to another work cell. This saves time and money.
7. Quality assurance
CNC machining produces fully functional, full strength finished parts and components. These can be used for full performance testing and certification, or to build working models. This is an important advantage if you’re developing a product that needs to meet more stringent engineering requirements.
Quality also extends to surface finish and appearance. Using the right cutting tools at the right cutting speed produces surface finishes that require little finishing. This in turn saves time and money, so you get the prototypes you need faster.