CNC Shops are Advancing Beyond Machining

The sudden change required this past year for many shops to switch overnight to PPE and ventilator production is a prime example of the supply and demand challenges of CNC machine shops. Serving the client in an ever-changing manufacturing environment means that CNC shops are advancing beyond machining with investments in technology, new views on skilled trades, and full-service operations.

Processes that reduce cost and improve flexibility are now the focus, but many of them fall outside of the manufacturing realm. Tooling can’t get much more efficient with 5-axis standards. Here we review some trends and technologies that broaden the scope of the customary CNC machine shop.

Updated Software

Before computer numerical control (CNC) manufacturing, shop work was done exclusively with manual machinery able to function only with a person present. The manufacturing time was much slower, but it also caused significant errors in setup, finished products, and material waste.

Incorporating computers into manufacturing continues to increase the speed and accuracy of manufacturing equipment in huge strides. Programming commands into the computer software and setting up the raw material is all that is required to process a finished product to near perfection.   

Today all custom machining services have CNC as their core element. From milling, lathe, precision cutting, and turning, every manufacturing activity is done through CNC machining to maximize the economy of scale.

As this precision cutting has neared its highest efficiency and accuracy, it is the software that will make the most difference in operations. Software adds intelligence to design, production, scrap reduction, and feedback that elevates the CNC process at every operation.

New measures in virtual reality and feedback from software to correct programs are the new differentiators. This will require a new staff focus of hiring more IT staff in place of machine operators, and even machinists.

Robotics

With the IoT, CNC machines can be operated remotely without first-hand human interaction, significantly reducing the risk of workplace hazards. Robotics add much more than safety. Programming tool setting reduces human error. Many CNC machines are fitted with multiple tools ready to be loaded by programming robotic processes. Robots are also available to feed multiple machines or move a finished part on to a second operation.

Robotic operations can be present on a single machine or encompass the whole machine floor. They are relieving, most recently, the strain on production during personnel shortages or social distancing requirements.

CAD programming can also transfer a program from one machine type to another through intelligent software and automated systems that react to these changes.

Varied High-Production Machine Approaches 

The trend to smaller part runs increases the idle time of expensive equipment, and so does switching over to other jobs during a high-production run. This is being addressed with innovative multi-spindle and rotary transfer machine design modifications to allow for greater versatility. Robots, of course, add to efficiency with their ability to feed and fit cutting tools as well as raw materials, further reducing downtime.

Lights out production, on the other hand, allows large production to run completely free of staff intervention. This leaves the problem of an early morning backlog of parts inspection by staff unless equipment is fitted with measurement technology through IoT, like vision systems, that can assess measurement during production.

Some machines are providing cost savings by becoming more specific instead of versatile. The production of large CNC machines designed for only lighter materials, like aluminum, dramatically lowers the cost of capital outlay but provides the same tight quality as machines that can handle heavier material like steel and titanium. These innovative approaches keep overhead costs down in industries like aerospace.

Full-Service Shops

As CNC machining becomes more accessible, it is the client services that will gain the most repeat business. Efficiencies and cost always matter, but modern manufacturers are looking at equipment and systems that will enable after manufacturing, the finishing, packaging, and maybe even storage of product for customers.

The expertise CAD operators can offer for ease and speed of the manufacturing process can often assist engineers in their design process. This provides an invaluable partnership between the client and the manufacturer.

As CNC shops are advancing beyond machining, new successful manufacturers will apply these full services, smarter automation, and software that practically runs the shop. It may not be a too distant future when the term “machining” becomes secondary to the services provided by cutting-edge shops.

Get in touch with us to see what is possible