Can We Combine CNC Machining With 3D Printing to Fabricate Prototypes?

There are situations the place we’re requested to CNC machine elements, product or a prototype which might be both exhausting to machine, too sophisticated geometrically, won’t yield nice accuracy or just can’t be machined. What can we do? For these situations, 3D printing the elements is usually a nice answer. So why not substitute CNC machining with 3D printing each single time? Effectively, there are benefits and drawbacks, professionals and cons for every machine and course of. So, which one is finest for our wants? Through which circumstances can we want one over the opposite? And is there one other answer that may mix these two collectively to create a combo half?

The essential distinction between the 2 processes is that with CNC machining we’re lowering materials as we begin with a foam block for instance, carving it away; whereas with 3D printing we’re layering on and including materials till we obtain the ultimate product, subsequently known as additive manufacturing.

The 3D printer makes use of the identical supplies that make up the half it’s creating, as an illustration ABS PLA and nylon, however it can’t swap between supplies, whereas in CNC machining we are able to use a number of kinds of supplies, typically including extra supplies on the finish. Nevertheless, machining may be messy – Generally we have to use a mud collector whereas working a CNC router machine to catch all that extra made within the drilling, carving and milling course of, whereas there’s much less waste materials produces in printing and the entire course of is much less noisy.

CNC machining may be extra exact offering extra accuracy as a result of the machines have the next tolerance for warmth. It might probably additionally lead to a a lot smoother polished floor end given the supplies to be machined. 3D printers can really distort an element, bend and warp if utilizing an excessive amount of warmth on the layered materials, so if distinctive smoothness is required the 3D printing will fall brief.

3D printing is mostly a neater extra handy course of and never as labor-intense as CNC machining, since with machining we have to program, write a G-Code, arrange totally different instruments and pace, resolve on slicing path and clear up after. Nevertheless, the half measurement performs a job, as bigger elements take longer to be printed including layer by layer. Total, 3D printing can help in some circumstances of prototyping of excessive geometric complexity the place the router software can’t attain inside the form.

3D printers can solely use the world of the printer mattress itself to manufacture the elements. Due to this fact, if massive scale elements are wanted they may not be capable to slot in there. It is usually not really useful for mass manufacturing because the supplies are far more costly and take far more time to manufacture. Due to this fact, 3D printing is extra applicable and more cost effective for low quantity manufacturing.

CNC machining can hardly ever run unattended and requires expert operator, whereas with 3D printing we are able to simply run the method unsupervised and it requires minimal coaching for its operator. Nevertheless, CNC machining is an older apply (began within the 40’s) and at present nonetheless has a stronger place within the manufacturing trade. 3D printing is comparatively new and nonetheless evolving to be extra helpful and adaptable and nonetheless can’t be a full alternative for machining.

In abstract, essentially the most applicable method to make use of might be decided by the fabric, geometric complexity, manufacturing quantity and our finances. As a common steering, we’d swap to 3D printing principally if quick turn-around in vital, if the half is just too advanced to be machined, for prototyping small volumes and if we have to use sure supplies that can’t be simply machined.

Having named many of the professionals and cons for every method, apparently there’s a good answer that really combines the 2 collectively to create one half. We frequently machine elements of the specified product utilizing a CNC router, whereas fabricating different small but extra advanced elements within the 3D printer, we then glue all elements collectively to make one unit. An alternative choice is then to coat all glued mixed elements with exhausting coat resembling Polyurea, Styrospray or epoxy, then clean and paint them. That approach we each save time utilizing the CNC machining course of in addition to with the ability to manufacture extra advanced elements combining the perfect of the 2 worlds collectively to create a hybrid.