Online customized CNC milling services for rapid prototyping and production of parts. We have a quality management system and certification to provide you with comprehensive solutions, from preliminary design to final product delivery, to ensure consistency and reliability of processed parts. The tolerance accuracy is ±0.005mm.
CNC milling increases with the number of axes, the flexibility and machining capacity of the machine increases, by using different CNC milling machines to accurately machine the required parts for a convenient manufacturing solution.
3-axis CNC Milling
This is the most basic configuration and includes three linear axes, X, Y and Z. Through the combined motion of these three axes, machining of flat or simple surfaces can be achieved.
Five-axis CNC milling is a technology that enables efficient and precise machining of workpieces at complex angles and orientations through the linkage of five independent axes.
Customized CNC machining services can meet the specific needs of customers, whether it is small batch or single piece production, and can be processed according to the design drawings or specifications provided by customers. This flexibility is particularly suitable for the early stages of product development, prototyping, or production of special parts, without the need for significant investment in molds or traditional manufacturing tools.
High Precision and Quality
CNC (Computer Numerical Control) machining is renowned for its high degree of automation and precise control, which can achieve extremely high machining accuracy and surface smoothness. This is particularly important for parts that require precise dimensions and strict tolerances, such as industries such as aerospace, medical devices, and semiconductors.
Aluminum alloy, with low density, good conductivity and corrosion resistance, is widely used in aerospace, construction, transportation and other fields. Aluminum 6061, 6061-T6 Aluminum 2024 Aluminum 5052 Aluminum 5083 Aluminum 6063 Aluminum 6082 Aluminum 7075, 7075-T6 Aluminum ADC12 (A380)
Widely used in the manufacturing of mechanical parts. Carbon steel has good mechanical properties and its hardness and toughness can be changed through heat treatment. Steel 1018, 1020, 1025, 1045, 1215, 4130, 4140, 4340, 5140, A36 Die steel Alloy steel Chisel tool steel Spring steel High speed steel Cold rolled steel Bearing steel
High strength, low density, good corrosion resistance, used in aero-engines, medical devices and other high-performance areas Magnesium Alloy AZ31B Magnesium Alloy AZ91D
One of the lightest engineering metal materials, used for 3C product housings, automotive parts to reduce weight. Titanium Alloy TA1 Titanium Alloy TA2 Titanium Alloy TC4/Ti-6Al 4V
It is a commonly used thermoplastic with good mechanical properties and impact strength, easy to process, and widely used in prototyping and industrial parts.
Nylon is widely used in engineering parts because of its excellent mechanical properties, abrasion resistance and chemical resistance, but its moisture absorption needs attention.
PC has high toughness, good mechanical processing performance, and excellent impact strength, making it suitable for applications that require high strength and transparency.
POM has very high mechanical strength and hardness, good abrasion resistance, and is one of the engineering thermoplastics with the highest machinability among plastics.
PTFE has a very low coefficient of friction and excellent chemical resistance, making it suitable for applications requiring lubricity or corrosion resistance.
TYPES OF SURFACE TREATMENT PROCESSES
There are a wide variety of surface treatment processes designed to enhance the performance of a part, such as increasing corrosion resistance, wear resistance, aesthetics, or other specific features.
Electroplating
Using the principle of electrolysis to deposit a layer of metal plating on a metal surface, such as zinc, copper, nickel, chromium, etc., to enhance corrosion resistance, wear resistance or decorative properties.
Anodic Oxidation
Especially for aluminium and aluminium alloys, it generates a dense film of aluminium oxide by electrochemical reaction, which improves corrosion and abrasion resistance, and can also be coloured.
Wire Drawing
A process whereby a specific tool is used to create long, thin, parallel filigree marks on a metal surface, giving it a unique texture and visual effect.
Sandblasting
The use of a high-pressure jet of abrasive material (e.g. grit) to remove surface impurities and provide a uniform roughness that facilitates the adhesion of subsequent coatings.
DLC Coating
An amorphous thin film of carbon, similar in structure and properties to natural diamond, but without the crystal structure, DLC coatings are widely used in industry due to their excellent properties.
Marking
Although not a surface coating treatment, laser marking can leave a permanent mark on a metal surface for identification, tracking or decorative purposes.
CNC MILLING TOLERANCES AND STANDARDS
We follow the ISO 2768 standard for CNC machining.
Maximum Part Size
1200 x 800 x 500mm
Minimum Part Size
5 x 5 x 5 mm
Precision Tolerance
±0.005 mm
Distance Dimension
+/- 0.005mm for features of size (length, width, height, diameter) and position (location, concentricity, symmetry)
Minimum Wall Thickness
Metal: 0.8 mm; Plastic: 1.5 mm. The thicker the wall thickness, the better the structural integrity.
Hole
Minimum diameter 1 mm. for best results, the depth of the hole should not exceed 4 times the diameter.
Threads and Tapping Holes
Diameter φ1.5-5mm, Depth: 3 times the diameter. Diameter φ5mm or more, depth: 4-6 times the diameter. We can produce threads of any size and specification according to customer requirements.
WORKING PRINCIPLE, ADVANTAGES AND APPLICATIONS
1. What is Milling?
1. Milling is a machining process that utilizes a rotating multi-flute tool (called a milling cutter) to remove excess material from a workpiece in order to obtain the desired shape, size and surface finish. In milling, the milling cutter is mounted on the spindle of a milling machine and rotates at high speed, constituting the main motion; at the same time, the workpiece may be fixed to a table, and the removal of material is accomplished by the transverse, longitudinal, or vertical movement of the table, and by the feed motion of the milling cutter. Alternatively, in some cases, the workpiece is held stationary while the milling cutter is moved along a plurality of axes.
There are various types of milling machines, including horizontal milling machines, vertical milling machines, gantry milling machines, etc., and many modern milling machines are CNC (numerically controlled) machines, capable of precisely controlling tool paths and machining parameters through computer programs to achieve high precision and efficient machining. Milling is suitable for machining a wide range of materials such as metals, plastics and wood, and is one of the widely used machining technologies in the manufacturing industry.
2. Milling equipment is divided into vertical processing and horizontal processing
Vertical Machining Center
Milling is a machining method that removes materials by cutting metal with high-speed rotating cutting tools. A vertical machining center is a machine tool that achieves milling processing through a vertical layout of the spindle structure. Due to the vertical arrangement of the spindle, the tool moves up and down along the spindle direction and horizontally along the top of the workpiece.
Horizontal Machining Center
Milling is a machining method that removes materials by cutting metal with high-speed rotating cutting tools. A horizontal machining center is a machine tool that achieves milling machining through a mechanism with a horizontal layout of spindles. Due to the horizontal arrangement of the spindle, the tool moves back and forth along the side of the workpiece to effectively discharge chips. Horizontal machining centers can also be equipped with dual exchange workbenches to achieve unmanned operation and shorten workpiece processing cycles.
2. Milling, as a commonly used machining method, has the following main advantages:
Flexibility and Versatility
The milling machine can be equipped with a variety of tools, capable of accomplishing a variety of types of machining operations.
High Machining Accuracy
Especially CNC milling machines and machining centers are able to achieve high machining accuracy, up to 10μm dimensional accuracy and R a=1μm surface quality in some cases, which is suitable for the manufacture of precision parts.
High Productivity
By centralizing the process, the number of clamping times and processing preparation time for workpieces are reduced. At the same time, it has fast feed and positioning functions, which improves the overall processing efficiency.
Strong Adaptability
Suitable for processing complex shaped parts, including spatial surface contours, thanks to the multi axis linkage function of the CNC system.
Good Surface Quality
Especially with smooth milling and appropriate cutting parameters, good surface finish can be achieved.
High Degree of Automation
CNC milling can realize automatic processing, reduce human errors and improve the stability of mass production.
3. Application
CNC milling is used in an extremely wide range of applications covering numerous industries and fields, mainly including:
Manufacturing
Suitable for parts processing in automotive, aerospace, marine, heavy machinery and other fields, capable of manufacturing complex geometric shapes and high-precision mechanical parts.
Mold Manufacturing
Used in the manufacture of various molds, such as injection molds, die-casting molds and stamping molds, etc., to ensure high precision and long life of the molds.
Electronics Industry
Processing of precision electronic parts, such as slots, housings, connectors on circuit boards, etc., to meet the demand for miniaturization and high precision.
Medical Devices
Production of precision medical device components such as surgical instruments, implants and small medical instruments that meet strict hygiene and dimensional standards
Art and Decoration
For engraving and finishing artwork, trophies, decorations and personalized gifts, showing fine details and surface textures.
Architecture and Furniture
Production of architectural models, windows and doors, furniture fittings and decorative panels with customized shapes and finishes.
A CNC turning is the workpiece rotation and tool movement for cutting, suitable for machining rotary parts; CNC milling is the tool rotation and the workpiece is relatively static or mobile, suitable for machining flat, curved surfaces and complex shapes of the parts.
A The CNC milling machine converts the uploaded CAD design into computer instructions that determine tool control. Next, fix the workpiece onto a vise, clamp, or fixture plate. When the cutting tool (usually an end mill) moves to the initial milling position, the rotating tool begins to feed the material at a predetermined feed rate and speed. Meanwhile, multi axis motion allows the tool to move on the workpiece and shape it.
In addition, there are two different types of workpiece motion possible in CNC milling. In the first case, the workpiece moves in the same direction as the rotation of the tool, which is referred to as conventional milling or counter milling. In the second case, the tool rotates against the direction of the feed, known as conventional milling or smooth milling.
The working principle of drilling is to use a rotating drilling tool to remove material from the area that needs to be drilled. Like CNC milling, computer-controlled drilling tools. After positioning the workpiece to the drilling coordinates, the drill bit begins to rotate and enter the material (usually along the Z-axis) to create a precise and clean hole.
A Aluminum processing, with a variety of different alloys to choose from, is one of the cost-effective metals in CNC machine tools. Due to its high machinability (slightly different depending on the alloy) and low raw material cost, aluminum is undoubtedly one of the popular metals in the field of CNC machining. Aluminum has a high weight to weight ratio, good corrosion resistance, and temperature resistance, making it widely used in industries such as aerospace, automotive, healthcare, and consumer goods. At RapidDirect, we offer a range of aluminum alloys for CNC machining, including the popular Aluminum 6061-T6, Aluminum 7075-T6, and Aluminum 6082.
Stainless steel (also available in a variety of alloys) is a popular and versatile material for CNC machining applications. While not as machinable as aluminum, stainless steel does offer a good ratio of machinability to low raw material costs. Stainless steel has many properties - including high strength, chemical resistance and hardness - that make it ideal for use in the automotive, aerospace, food, marine and healthcare industries. and chemical processing equipment; and 316 stainless steel, for more extreme applications such as those found in the marine or chemical industries. Of the three, 303 stainless steel is the cost-effective choice due to the presence of sulfur and phosphorus.
Brass is a metal alloy made from a combination of copper and zinc and ranks second on the list of cost-effective CNC machining metals. Brass has high machinability (better than stainless steel), although its raw material cost is slightly higher. However, brass has a high rate of scrap recycling, which reduces raw material costs.RapidDirect offers two brass alloys: Brass C360 and Brass C260, which have a high zinc content. Brass C360 is a cost-effective option for brass machining because of its softness, ease of machining and low impact on machining tools. Brass is generally known for its medium hardness and high tensile strength, making it suitable for use in electrical products, consumer goods, construction, automotive and healthcare.
Cost is one of the most important factors to consider when choosing manufacturing technology, and CNC machining is usually cheaper and more cost-effective than 3D printing.
Speed: As we have already stated, CNC is a faster solution than 3D printing.
Difficulty: Compared to industrial 3D printers, the installation and implementation of CNC machines are much easier. CNC machining makes prototyping easier as machines can carve designs from materials and build prototypes using the exact materials used to obtain the final product. However, 3D printers cannot produce prototypes with structural strength.
Quality: CNC can produce high quality and precision machined parts that 3D printers cannot match.
Product Integrity: Finished products retain the strength and other properties of the material after CNC machining, but 3D printing reduces the integrity of the part due to layering and the inability of the material to bond on a molecular level.
Volume: Based on speed and cost, CNC machining is more suitable for large-scale production than 3D printing. There are some drawbacks to mass production of 3D printers that have not yet been resolved
