How to Free Up Your CNC Machine Shop with 3D Printing

CNC Machining is an incredible application of technology that revolutionized manufacturing as early as the 1950s.

In this newsletter, we look at common challenges faced by businesses that operate CNC machine shops, and how two companies overcame these challenges by complementing their existing processes with intelligent Markforged 3D printers.

The Challenges of CNC Machining

The gradual development of control systems and more powerful tools like EDM and plasma cutters have made CNC popular in every area of manufacturing. In areas such as Printed Circuit Board (PCB) design where minute precision is essential, the benefits of CNC really shine.

This power comes at a price however. If you operate CNC machines, you’ll be familiar with these challenges;

1.?High Initial Costs

• It’s no secret that CNC machines are expensive, with high end models costing hundreds of thousands of pounds. Add the costs of software, materials, and training, and this can become a significant barrier to entry.

2.?Skilled Labour Shortages

• Operating CNC machines also requires skilled technicians who can program, set up, and maintain the equipment. With intense competition for these operators worldwide, finding (and retaining!) them can be a major challenge. ?

3.?Complex Programming

• Every new object has new geometry, and that means new programming for the machines involved. In addition to finding capable programmers, this adds a lead time on creating new objects.

4. Maintenance and Downtime

• Like any machinery, CNC machines require regular maintenance to ensure optimal performance. With such high operating costs, breakdowns are often emergency scenarios, and waiting for spare parts to arrive can cause devastating losses. While this can be mitigated with spare part stocks, this again has an associated cost with storage.

5. Tooling Costs

• Tooling is an often-overlooked factor of CNC machining; jigs and fixtures are required to hold materials in place and keep results consistent. If these secondary tools need to be machined, the costs and lead times can quickly add up.

6.?Production Volume

• Adjusting CNC machines for different production volumes can be challenging, sometimes requiring reprogramming and retooling. In addition, small batches of complex objects can be extremely expensive to manufacture with all the associated preparation.

How many of these affect your business? Leave a comment and let us know!

The good news is that all these challenges can be addressed with 3D printing.

Overcoming Challenges using 3D Printers

Let’s be clear; while Markforged 3D printers can be used to create strong and precise end-use parts, this isn’t the primary application on factory floors. CNC machines are well established and are very good at what they do, and 3D printers aren’t likely to replace them any time soon.

3D printers have some unique strengths however that make them excellent at complimenting existing manufacturing processes, making them more efficient.

Let’s take ASS Luippold Automation Systems&Service e.K. as an example. ASS Luippold are an industrial automation company based in Germany, who handle everything from planning and design to implementation of complete production lines, with their machines in use throughout Europe in a wide variety of industries, especially in the realm of PCB.

You can download the full case study PDF by clicking here (no sign-up required).

At a glance, ASS Luippold were able to make extreme weight savings on their robot arm grippers by replacing aluminium with light but strong composite parts, leading to 66% cost savings. The case study also details how their CNC milling department was freed up for work on core business, and prototyping was accelerated.

A key advantage in situations like this is that complex geometry doesn’t cost extra with additive manufacturing, meaning it’s possible to create a hollow but strong component without compromising the surface of the object.

Combining these precise, complex 3D printed components with larger, efficiently CNC machined components gives you the best of both worlds – and this is just one application.

In another example, watch Dixon Valve & Coupling demonstrate in this 2 minute case study video how a Markforged 3D printer freed up huge amounts of time for their machine shop, and allowed them to retool the robotic arms on their assembly line in under 24 hours instead of weeks.

What Next?

If you’d like to know more about Luippold’s applications, or more about Markforged’s technology, our team are always happy to help and give you the information you need.

You can call Mark3D UK Limited - The UK's #1 Markforged Partner on +44 121 661 1151, or alternatively you can follow this link to arrange a personal demonstration at your own facility.

We’re also attending events and running roadshows throughout the year across the UK! Click here to find out where you can meet a 3D printer in person.