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“What does CNC stand for?”

The name “CNC” stands for Computer Numerical Control. CNC machining is a process using computer numerical control (CNC) machines. They can be the tools such as mills and lathes guided by computer instructions that control the instruments.  

Subtractive manufacturing processes, such as CNC machining, are often presented in contrast to additive manufacturing processes, such as 3D printing, or formative manufacturing processes, such as liquid injection molding. While subtractive processes remove layers of material from the workpiece to produce custom shapes and designs, additive processes assemble layers of material to produce the desired form and formative processes deform stock material into the desired shape.

CNC relies on digital instructions from a Computer-Aided Manufacturing (CAM) or Computer-Aided Design (CAD) like Fusion 360. Once the CAD design is completed, the designer exports it to a CNC-compatible file format, such as STEP or IGES. While the CAM or CAD does not run the CNC machine itself, they provide the roadmap for the CNC. The CAM software writes G-code that the controller on the CNC machine can read. The computer program on the controller interprets the design and moves cutting tools and/or the workpiece on multiple axes to cut the desired shape from the workpiece. 

CNC machines used several programming languages, including G-code and M-code. The most well-known of the CNC programming languages, general or geometric code, referred to as G-code, controls when, where, and how the machine tools move— when to turn on or off, how fast to travel to a particular location, what paths to take, etc. Miscellaneous function code, referred to as M-code, controls the auxiliary functions of the machine.

A typical machine shop process looks like this: A design engineer creates the design in the CAD program and sends it to a CNC programmer. The CNC programmer opens the file in the CAM program to decide on the tools needed and to create the NC program (g-code) for the CNC. He or she provides a list of the correct tooling setup to an operator. A setup operator loads the tools as directed and loads the raw material (or workpiece). He or she then runs sample pieces and measures them with quality assurance tools to verify that the CNC machine is making parts according to specification. Typically, the setup operator provides a first article piece to the quality department who verifies all dimensions and signs off on the setup. The CNC machine or associated machines are loaded with enough raw material to make the desired number of pieces, and a machine operator stands by to ensure that the machine keeps running, making parts to spec. Depending on the job, it’s often possible to run CNC machines “lights-out” with no operator present. 

Who needs the Spyder CNC?

Spyder CNC looks like a router CNC, but it acts as a sturdy vertical CNC. It had multiple one inch diameter steel shafts, four Z-axis steppers, and double steppers on the X and Y axes. The APSX LLC brand controller software offers a very informative and clear user screen experience and advanced features such as stall detection with instant stop and mist coolant control.

So, be cautious when you compare the Spyder CNC to other desktop CNC milling machines with no advance features mentioned above. Those features make the metal milling pain free. 

The 4th axis feature adds more possibilities to your part portfolio. You can machine round shapes with the 4th axis rotary tool. You need to order the machine in this configuration.

The key to CNC Swiss turning is adding a bar feeder that spins the round bar and slides and feeds through the guide bushing in the Z-axis direction.

As a mini CNC Swiss lathe, the APSX-NANO has a max capacity of 20 inches long bar stock at a time. These machines provide stationary support for the workpiece while the part is machined. This design enables the machine to hold tight tolerances and produce parts back to back. 5 axis Swiss-type machines have milling and drilling capabilities.

It is best when parts have milled and turned features that require precision machining. Swiss CNC machining allows for many milled features (flats, hex edges, slots, left hand threading etc.) to be produced during the turning process without the need for multiple setups on additional equipment, providing greater production efficiencies with one process.

The rotary broaching process can be performed on these machines to cut standard or custom shapes into or onto a workpiece.

The ID centered rigid tapping or thread milling processes can be performed on the APSX-NANO CNC Swiss. You can also thread milling by using the live tools. There are multiple Swiss tooling companies that you can find a perfect tool for each application.

When smaller, more complex parts are needed. Typically, those parts are non-standard parts and can not be sourced directly. Examples would be tamper proof bolts, special nuts, pins, custom mechanical parts, nozzle inserts, pick and place tips, antique jewelry and watch parts, gunsmith parts, custom knives, custom musical instrument bolts and screws, fasteners, rc car and drone parts. Especially the screws (standard or custom) made out of Titanium (Grade 5) are expensive to buy. You can make them yourself by using the APSX-NANO CNC Swiss Lathe in house to save money and also make money by selling them.

Most of the Swiss-type parts are less than 1” (25mm) in diameter, with the majority being less than ¾” (16 mm) in diameter.

Aerospace, automotive, drones, firearms (small arms and ammunition) and electronics components with multiple applications.

Medical and orthopedics: Bone screws, anterior cervical plates, fracture components, bone drills, surgical taps, orthopedic devices, surgical instruments, bone shavers and more.

Dental: Titanium implants, dental taps and drills, abutments and locking screws, dental driver instruments, orthodontic components and more.

Minimally invasive surgery: Screws, plates, housings, distal tips, cones, connecting rods, pins, grippers, surgical drivers and more.

Military vehicles and aviation: Cargo handling systems, guided missile, fuel systems, cockpit instrumentation, seatbelt mechanisms, cabin pressure control, wing flap actuation, antenna control, drones and more.

3D printing has been an awesome way of creating products in recent years. We, as a company, used 3D printers to create prototypes from time to time. However, like any other current technology, 3D printing also has limits if your goal changes over time. For example, if you want to make more parts in the same amount of time, you need to add more printers to your printer fleet. Unfortunately, that may not be possible or feasible all the time.

APSX LLC received new customers from the 3D printing industry specifically for this main reason. These customers converted their production process into plastic injection molding. The roadmap from 3D printing to injection molding is pretty straightforward.

1 – The 3D drawing of the part

As a 3D printing business, you already have your part designed in a 3D environment (CAD). Sometimes a 3D printable part can not be a good candidate for injection molding. You can easily revise the features of the part so that it is compatible with injection molding. Some typical 3D file formats are STEP and IGES files. You can use Fusion 360 or Solidworks software or similar for that purpose.

2 – The 3D drawing of the mold

The next step in this process is to create the mold for injection molding in a 3D environment (CAD). You need to subtract the part from the mold surface to create the cavity on the mold. Now you can think about how you will make the mold in the next step. APSX LLC has 3D files for the standard size blank mold on its website. You can download it whenever you are ready to try this.

3 – Making the mold

Once you have the g-code out of the 3D software, you have the options (CAM):

a. 3D printing the mold: You can use high-quality (not PLA) 3D printer material that can withstand some level of clamping force and heat. The other good characteristic of the mold material is its high conductivity. That makes the mold cool down easily. The mold size can be a full-size mold or an insert type.

APSX LLC successfully tested sample 3D printed molds from the 3D printer companies such as Origin, Stratasys, MarkForged, Formlabs, Elegoo and Asiga.

b. CNC milling the mold on a high melt plastic block: If you want your milling process to be forgiving and easier, you can mill plastic material such as polycarbonate or other translucent material. That would also allow you to see how the injected material flows inside the mold. Follow the link here to watch.

c. CNC milling the mold on an aluminum block: The ultimate goal would be to mill the mold on an aluminum block. APSX SPYDER CNC machine is a good choice since it was designed with that purpose in mind.

Once you switch from 3D printing to injection molding, you will see its benefits in fully functional plastic parts, lower cost per piece, and much shorter production times. These are the essentials for a growing business to meet its increasing demand.

Please get in touch with us to receive more information about APSX-PIM and SPYDER CNC.

ADVANTAGES FOR INJECTION MOLDING

1 - Low scrap rates

CAUTIONS FOR INJECTION MOLDING IN A TYPICAL CONVENTIONAL INJECTION MOLDING APPROACH