Rapid Prototyping with CNC

“According to the concept, a CNC machine creates precise and intended shapes. It can quickly transfer the 3D designs into parts with desired functionality.”

The reason behind using rapid prototyping is that it provides the idea about functionality, economic feasibility, and overall scope of the product. In this context,  Prototyping with CNC can help you to prove your concept of parts or products.

There is a common assumption that a prototype is identical to production. However, it’s a different process, which includes testing, modification, and multiple iterations. This article will brief CNC prototyping process and how you can leverage this technology in your product development projects. 

Steps Involved in Rapid Prototyping with CNC

Developing a prototype with CNC machining involves several steps, from designing to surface finishing. Meanwhile, each step is essential to achieve the intended specifications on the Prototypes.

The following are the steps of the CNC prototyping process;

Chronological steps of CNC rapid prototyping

Step 1: Finalization of the design

Finalization of the design is the first step for prototyping with CNC machining. As we all know, CNC machines create the parts from the uploaded 3D model (or 2D drawing) that need to be finalized. In this step, designers and expert engineers create multiple possible designs without altering the functionality of required parts or products. The design includes complete dimensions, tolerances, features, and positioning. Once all the designs are ready, expert engineers select the few best designs for further proceeding.

Step 2: Creation of technical-drawing(3D model or 2D drawing)

CNC machines work on the 3D file, such as CAD design. Therefore, it is necessary to transform the chosen designs into 3D files like DWG and SLDPRT. All the dimensions, tolerances, features, and aesthetic requirements should be examined and validated according to the needs of the finished product while developing the 3D file.

Step 3: Identifying the machining processes

The machining steps are identified and finalized in this stage based on the 3D design. Identification of the manufacturing sequence is essential to optimize the time and material used for production. CNC machines can perform many tasks, including routing, CNC turning, drilling, and CNC milling. Therefore, it is necessary to decide which procedures were required and in what order, depending on the features included in the design.

Step 4: Production

CNC machining operation

The numerical control panel receives the uploaded CNC program when created. The machine is operated when the workpiece is mounted on the tool.

Once the machine runs, it completes all machining operations following the input settings. After multiple CNC machining operations, the desired prototype is produced. If the prototype has multiple parts, it requires a separate prototype and assembly later. This step is necessary for the prototype, which includes mechanical linkage and interconnected components.

Step 5: Testing of prototype

After production, the prototype goes into testing. It is the most crucial step of rapid prototyping with a CNC machine. The prototype’s functionality is tested, and all the possible failure situations are tested in this phase.

Along with the functionality, several other factors are analyzed in the testing phase, such as CNC machining defects, durability, and overall efficiency. After conducting the testing, the production expert approved the prototype for further production. If the prototype fails to fulfill the requirements, alternative designs are analyzed and go for production by following the same sequence of rapid prototyping.

Advantages of Prototyping with CNC

Rapid prototyping with CNC machining offers various advantages, from material selection options to flexibility in modification. Let’s overview some of them in detail.

1. Diverse working materials

Unlike additive manufacturing approaches like 3D printing, CNC machining is compatible with a wide range of materials. It can work with difficult-to-machine materials. Rapid prototyping With CNC machining provides the flexibility to the developers to choose the materials. It is also easy to understand the performance, economic feasibility, and appearance when made with different raw materials.

Our company offers a wide range of materials for rapid CNC Machining Services, following are some common CNC Machining materials;

2. Accuracy with prototyping

Since rapid prototyping requires accurate manufacturing, CNC machines can create parts with a high degree of accuracy. Because of the automated production, tight tolerance is easily achievable with each machining operation, such as cutting, drilling, turning, routing, and many more. CNC tolerance of ±4 μm is readily achievable, which is accurate enough for almost every type of part and product.

Digital Instruction to the CNC Machine

If we compare CNC rapid prototyping with conventional approaches, it is far more accurate. It eliminates the risk of human error, and exact parts can be created as uploaded 3D designs.

3. Quick lead time

Because of the automatic production nature, CNC machines create prototypes in a few hours. However, the complete process from design to testing can take a few days.CNC machines reduced manufacturing and assembly time. All the tools and set-up work in a quick manner. Spindle speed, feed rate, and other circumstances do not restrict the production time of the prototype.

It offers a quick lead time and allows developers to test the prototype in a short time. It is highly advantageous to modify in case of any defects. prototyping with CNC  is crucial, especially for developers who want to maintain their market advantage and outperform rivals.

4. Cost-effective

Cutting Tool changes are not frequently necessary when developing the prototype with a CNC machine. This phenomenon shortens production time. With the ability to manage resources and quality, the cost of prototyping was reduced significantly. So, it is a cost-effective approach to prototype development.

5. Easy for modification

Since CNC prototyping is a speedy process, it enables engineers to modify the parts and products in a matter of hours in case of flaws or functional deficiencies. Developers can rapidly swipe the models after testing. It simplifies testing and reduces the possibility of error.

6. Easy to change

CNC machines are completely computer-controlled systems that enable quick changes in the design into CNC G codes and M codes. If you use the concept of continuous improvement, you may quickly adapt and modify your prototype. On the other side, it will cost more to alter and change the prototype using different techniques, such as 3D printing and injection molding. Quick design and program changes save not only money but also time.

7. Outstanding Result

CNC machine offers high-quality manufacturing for a few to hundreds of prototypes. The finished prototypes become functional and high strength. The as-machined surface finish also provides roughness in the range of Ra 3.2 micrometers, which is pretty well compared to other approaches like 3D printing (Ra 15 micrometers).

8. Complex prototypes

Complex prototype of automobile part made with CNC

Prototype with complex geometries is easily created with a range of CNC machining operations, such as milling, drilling, turning, routing, and many more. It also offers precision in complex parts because of the automated production.

Disadvantages of CNC Prototyping

There are only two major disadvantages of CNC machining on rapid prototyping, Material wastage & restriction for some complex geometries.

1. Material wastage

As a subtractive manufacturing method, CNC machining produces parts by removing materials from the workpiece. The material gets wasted during the removal process in the form of chips. In essence, you require more material than you will ultimately use.

2. Challenging for complex geometries

With CNC machining, some hidden geometries can be challenging to produce as the tool goes from top to bottom. Compared to CNC machining, other production techniques like 3D printing may make it easier to create complicated shapes.

CNC Prototyping Metals

At Prolean, we stand at the forefront of metal prototyping. Our metal rapid prototyping solutions cater to those in need of top-tier quality and precision. From the sleek design of an Aluminum Prototype to the resilience of Brass, Copper, and Titanium, we’ve got an array of choices for you. Our expertise doesn’t end there. For those seeking the dependability of Alloy Steel, Stainless Steel, or Cast Iron, we provide prototype sheet metal parts that are second to none.

• Aluminum Prototype
• Brass
• Copper
• Titanium
• Alloy Steel
• Stainless Steel
• Cast Iron

Plastics for Prototyping with CNC

• ABS
• Acrylic
• Delrin
• Garolite G-10
• FR4
• Polyethylene (PE)
• Nylon
• PEEK
• Polycarbonate（PC）
• Polypropylene(PP)
• PPSU（Polyphenylene
• Sulfone resins）
• PPS (Polyphenylene
• Sulfide
• PTFE (Teflon）
• Polyetherimide (PEI)
• PMMA (Acrylic)
• PVC

Is CNC Machining Best for Rapid Prototyping?

Yes, CNC machining is best for Rapid Prototyping. Prototypes show how the final product will behave and provide a visual picture. Before mass manufacturing, it is a valid scientific approach to confirm the product’s original requirements. It allows the identification of failure points and offers areas for improvement. Additionally, prototypes are utilized to direct the R&D process or show investors the results. The importance of prototyping in the product development process makes it crucial to adopt cutting-edge manufacturing technology that enables high-end precision.

Rapid Prototyping Services

If you believe that 3D printing is mainly used for rapid prototyping, your idea may not be accurate, you can check “CNC machining vs. 3D printing” for the difference. For rapid prototyping, developers prefer CNC machining over 3D printing. CNC machining provides a variety of material choices, making it simple to choose the one that best matches the desired characteristics and properties. Accuracy is another factor, the CNC machining approach offers accuracy and an excellent as-machined surface finish. However, 3D printing might be more appropriate for smaller plastic products.

Why Choose Us for Custom Metal Fabrication Prototype Services?

We combine experience with the latest technology, ensuring every metal prototype meets your exact specifications. Our metal prototype fabrication process is streamlined and efficient, offering metal prototyping services that turn visions into tangible solutions in as little as two to three days.

For businesses and individuals needing prototype sheet metal fabrication or seeking metal prototypes, our team is committed to excellence. We are recognized as one of the leading metal prototype manufacturers in the industry. Every piece, be it metal prototype parts or comprehensive prototype metal fabrication projects, is crafted with attention to detail.

Upgrade your prototyping process with Prolean

The advanced and fully automated CNC machining system at Prolean provides a professional prototyping service for your parts or products faster than you thought possible. You can innovatively machine almost every material with precision in hours once you finalize your 3D design. We also run the computer simulation for the sensitive parts to visualize the prototype’s performance before it undergoes production. You will get your prototype on your desk within a matter of days. In addition, we also provide ongoing technical support after the delivery.

Conclusion

Before going into mass manufacturing, rapid prototyping is the best choice for product creators to test the product’s technical and financial feasibility. Rapid prototyping with CNC is the ideal option to check the visual aspect and functionality of the product. CNC machine offers a wide range of material options with a high degree of accuracy and surface finish with only a few days lead time; the process is quick. Additionally, it enables rapid testing and modification of the product if any adjustments are required.

Rapid prototyping is a strategic and complex process. It required expert engineers and experienced operators for different sensitive tasks. Sensitive tasks include selecting machining sequences, creating CNC programs, and machine handling. Prolean offers rapid prototyping for your parts and products with high-end precision. We optimize prototypes’ functionality, material uses, features, and tolerance.

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