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Advantages of CNC Machining
CNC machining stands for “computer numerical control” machining. It is a relatively new process in the world of machining which allows for increased efficiency through higher levels of automation and by allowing the machine and it’s computer controls to do all the work. While CNC machines are expensive and complicated, they quickly pay for themselves by reducing the workload and preventing errors.
The first major advantage of CNC machining is that it improves automation, removing the need of an operator for all but a few parts of the work. CNC machines can be left unattended for hours or even days if necessary, allowing operators to focus on other tasks. This also allows for a company to retain fewer operators, thereby saving on overhead. By removing the operator, safety is also increased, since should there be a jam or other potentially dangerous machining error, the operator will not be holding the tool and the only thing damaged will be the tool itself. CNC machines can also work much faster than human machinists, since they are faster, stronger, and do not need to take breaks. They can also be run late at night, when most of the workers have gone home, since machines do not need to worry about being sleepy or getting paid overtime.
The second big advantage to CNC machining is that it produces an exact result every single time. Even the best human operator will have minor variations between finished results, whereas a CNC machine will produce exactly the same result each and every time it is run. This is very important in the modern world of standardized and interchangeable parts, where a single defective cut can make an entire machine wholly unusable. All that is necessary is for a single program to be developed and placed into the machine. Then the machine can toil away at however many work pieces are needed, producing an exact replica down to thousandths of an inch each and every time.
The third big advantage to CNC machining is the flexibility of the machine itself. While humans are much more flexible and trainable than machines, a CNC machine can be completely reprogrammed in a matter of hours to produce a completely different product. It is thus possible to refer back to old programs or install new programs when a different work piece is required. This gives CNC machines a big advantage over other machines, since they can quickly shift to producing a completely different product without the installation of many new parts or a major overhaul of key components. This also ensures that CNC machines can keep up with customer demand, since they can very quickly shift from making a part that is in surplus to a part that is lacking should a need arise.
To learn more, check out this great resource for CNC Machining.
Why Is Prototyping Important?
Whatever the item a person or a company intends to produce, creating a prototype is a crucial step in the design process that cannot be glossed over. Why is prototyping important? There are several main reasons; testing and evaluating the design, clarifying production issues and costs, selling it to others, as well as making clear any patentable details.
Evaluating and Testing the Design
Unfortunately, ideas and drawings of a design can sometimes be a far cry from the real world in which the product will be used. By creating a prototype it is possible to sit down with a real version of the product and determine which aspects are worthwhile and which parts need to be revised, changed, or discarded. In the process, it may be possible to find glaring omissions that, on paper, weren’t noticeable.
Additionally, creating a prototype will allow the design team to not only evaluate, but also test the product before going into full production. Imagine ordering tens of thousands of units, only to discover one part isn’t as strong as it needs to be. If corporate giants can make mistakes, it is all the more important for smaller companies to not forget the importance of prototyping before beginning production.
Clarifying Production Costs and Issues
Once production begins, it is costly and time consuming to make changes. By prototyping before production begins, it is possible to take a glimpse at the production process and see if any steps can be changed, combined, or even removed. This not only streamlines production, but keeps the?cost of the actual production to a minimum. Subsequently, if there are any difficulties in production or perhaps processes that can create problems for the final product, it is much better to see these before production starts. It can also help the design team ascertain the optimal method for production; injection-molding, silicone molds,?stamped metal, etc.
Selling the Product to Others
Just like it is far easier to see if there are any problems with a design by holding an actual working model, it is also far easier to sell to potential customers when they have a prototype to hold and manipulate at a marketing presentation. Without a prototype it’s only a concept. It can be difficult to get a?client to commit to a purchase of a concept. With a prototype in hand, the concept instantly becomes real and it is far easier to sign a purchase order.
The customer needs to be taken into consideration during the prototype phase as well. No matter how great the designers and testers think a prototype may be, real consumers may not like certain aspects of it. If the end customer doesn’t like it, they won’t buy it, which is why focus groups and external testing with prototypes needs to be addressed before production begins.
Patents
If a product is new enough or unique enough, patents need to be considered. It’s no use to design and manufacture a great product only to have another company start producing a remarkably similar product because the original company failed to patent key aspects of the design. By having a working prototype, it is much easier to sit down with a patent attorney and see what design aspect may be patentable. On the reverse side, it is possible to see what parts of the prototype and design violate patents of other individuals and how they can be changed before production, and the chance of a lawsuit, begins.
Contact TenX today and get a high-quality prototype fast! 715 235-8474.
Benefits of Rapid Prototyping
Rapid Prototyping is a term used to describe many manufacturing processes that are able to quickly convert 3D CAD models into physical parts. Some of the technologies used in rapid prototyping are stereolithography (SLA), CNC machining, urethane casting and quick-turn tooled injection molding. Many of these rapid prototyping processes produce parts that are at or near production quality, which can be very beneficial at many points during product development.
The greatest benefit of rapid prototyping is the ability to test various part concepts quickly. Even the best engineers and designers are regularly surprised by what can be learned by evaluating and testing a representative part. Details that may not be apparent on a CAD system or on paper will show up readily in a rapid prototype. This eliminates costly mistakes, improves the quality of the design, and allows more valuable iteration cycles of concept to prototype.
Rapid prototyping is often a very low cost option for constructing prototypes, especially when the cost of the time to manufacture a prototype using more traditional methods or waiting for first tooled pieces is factored in. While the cost for rapid prototype parts is almost always higher than production parts, tooling outlays are minimal. When it is time to move to production tooling, rapid prototyping will likely have minimized mistakes that would otherwise have resulted in costly tooling revisions or remakes.
Rapid prototyping also provides the opportunity to conduct market studies with prototypes that have a realistic look and feel. Gaining early data on how the market accepts or reacts to the product is valuable information which can be used to improve the design and ultimately increase sales.
Product development is often very sequential, but rapid prototyping places efforts in parallel. Once a design has been completed, rapid prototyping can be used to push a product to market quickly capitalizing on any window of opportunity while long lead-time tooling is underway. This yields greater control over a product’s launch and early market adoption.
Rapid prototyping should be an integral part of almost any modern manufacturing organization’s new or sustaining product plan. The benefits of speeding iteration, improving design quality, lowering costs, providing a tool to evaluate the market, and going to market quickly provide more efficient development cycles which will result in better products with better profits and revenues.
View TenX Manufacturing’s Process Featured on Manufacturing Marvels
TenX recently had the opportunity to showcase its cutting-edge manufacturing services and capabilities on Manufacturing Marvels, a segment from the Fox Business Network. This feature highlights our comprehensive approach to manufacturing, which includes everything from the initial design phase to the rapid prototyping process, as well as the precision of injection molding techniques. The segment offers viewers a deep dive into how TenX Manufacturing stands committed to customer satisfaction through innovative solutions and meticulous attention to detail at every step of the manufacturing process. Watch the entire segment to learn more about TenX’s dedication to quality, efficiency, and innovation in manufacturing!
Beating the Competition to Market
The old saying, “first come first serve” can hold true in many scenarios, and it is clearly evident in the competitive marketplace we function in today. That’s why being the first one to market with a new product has proven to be a winning move, and its being done by utilizing cutting-edge rapid prototyping methods. A big buzz word in the ‘Rapid Prototyping World’ right now is 3D-Printing, if you haven’t heard of it by now, you’re living under a rock! The process isn’t exactly new, but the advancements in technology over the last 30 years have been substantial, and the forecast for the next 5-10 years looks to be nothing short of amazing. 3D-Printing has quickly evolved into the most commonly used form of prototyping for companies looking to push their new products to market, but it’s certainly not the ONLY.
In the shadow of 3D-Printing we’ve lost some sight of some tried and true methods that continue to give companies a competitive advantage in the manufacturing process, and probably the most overlooked and unknown is Urethane Casting.
- Urethane Casting & it’s benefits
- This process starts with a 3D Printed part to create a master pattern, the master is then encapsulated with silicone, once the silicone is parted into 2 halves and the master removed, the ‘soft tool’ is created. That ‘soft tool’ can now be used to create urethane parts; urethanes can be of nearly and durometer and mimic most injection molding materials. The casting process allows for difficult geometries due to the forgiveness of (silicone) soft tooling.
- The cost and creation time of a soft tool is significantly less when compared to a standard injection mold.
- The limitations companies experience with some lower-end 3D-Printers yield to the advantages of Urethane Casting in terms of material, size, & color.
- Small or Large cast parts can produced in one solid piece, as opposed to many
- One ‘soft tool’ can be used to produce the same part in numerous materials and in-office 3D-Printers that have small build platforms. colors.
In the ‘market-race’ keep in mind that time peels off the clock at the same rate for everyone, and the person who utilizes every tool possible to save time will often be a step ahead of the competition.