Metal 3D print or CNC machining

Choosing the right manufacturing method has a significant impact on the physical and economic performance of a product.

While 3D printing technology is becoming more mature, customers still need to carefully consider whether it brings greater advantages for their specific applications compared to traditional Computer Numerical Control (CNC) production.

When selecting a manufacturing process, the following 5 aspects should be considered.

3D Printing is not a "Simple" Button

Many individuals who have not been exposed to metal 3D printing or are relatively new to it might mistakenly believe that metal 3D printing only requires pressing a "simple" button.????????????????

Common Misconceptions about 3D Printing:

Another common misconception is that using 3D printing for in-use parts will be cheaper or faster.

This is only true when the component has many cavities and was initially designed for 3D printing.

If the part is designed for CNC production, the additional value that metal 3D printing can provide may not be fully utilized.

CNC Machining as a Subtractive Manufacturing Method:

CNC machining is a subtractive manufacturing method where the material is removed from a solid block based on CAD models.

The more complex the part, the longer the production time.

For example, a threaded shaft can be manufactured on a lathe, while a complete blade (as shown in the figure below) requires a full 5-axis milling machine.

Harder metal materials require more specialized and expensive cutting tools.

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Melting-Based 3D Printing Process:

The melting-based 3D printing process involves "growing" a part on a substrate, layer by layer, using a series of micro-welds.

After the melting and solidification of metal powder, internal stresses often occur.

Rapid temperature changes and high-temperature gradients cause each layer to attempt to curl upwards during the construction process.

Therefore, some low-angle surfaces and cantilevers during construction rely on support structures to be fixed to the substrate.

After construction, these supports need to be removed, posing a risk of damaging critical features of the product.

In summary, the choice between 3D printing and CNC machining depends on factors such as part complexity, material considerations, and the desired production speed.

Each method has its advantages and disadvantages, and understanding these factors is crucial in making an informed decision for a specific application.

3D Printing and CNC Machining Each Have Pros and Cons

For 3D printing, the impact of part complexity and the choice of materials on the production cycle is much smaller.

When parts have features like keyways, slots, or curved profiles, such as in manifolds, 3D printing becomes more valuable.

In additive manufacturing, less is often more.

CNC machining, on the other hand, involves subtracting material and has entirely different cost-driving factors.

Different Considerations for Designing for 3D Printing

For 3D printing, the design of components needs to consider the set build direction. Ideally, through optimized design, the goal is to minimize the need for support structures.

Design considerations should include the fixed direction from bottom to top and the anticipated core functionality of the part.

Since support structures are also made of metal, they increase material consumption, build time, and the post-processing required for support removal.

Design engineers must have a comprehensive understanding of the entire workflow to unlock the true value of metal additive manufacturing.

Transitioning from CNC to 3D Printing Can Be a Challenge

Companies exploring the shift from CNC machining to 3D printing often focus on studying the cost of producing the same components using traditional manufacturing methods.

However, this approach is fundamentally inappropriate.

CNC machining has evolved over several decades and is a highly matured process.

Parts produced with CNC may have undergone numerous optimization designs over the years, with many assumptions considered commonplace due to the best practices developed.

In the world of 3D printing, many aspects must be rediscovered, replaced, and validated. These necessary steps often introduce additional complexity during product design and approval processes.

In terms of cost, traditional machining processes such as milling or turning almost always prove to be more economical in mass production scenarios.

Cracking and warping are common challenges encountered when attempting to 3D print parts designed for CNC.

Unlike 3D printing with plastics, the material cost for metals is considerably lower, but the risks are higher.

Due to the expensive nature of materials, equipment, and post-processing, a failed metal print can result in thousands of dollars in wasted powder and lost productivity.

In many cases, the success of printing a part is unknown until the construction is completed.

If the design of a part doesn't instill confidence within a certain range of successful construction, most service providers are reluctant to take the risk with an unverified design, given the high likelihood of failure. Challenging the technological limits to prove why a part needs optimization is disadvantageous for both customers and manufacturers.

Opro-tech offers a variety of 3D printing processes:

SLA photopolymerization technology, FDM fused deposition modeling technology, laser sintering technology, etc.

The company primarily produces SLA rapid prototyping, CNC prototype machining, SLM metal printing, SLS nylon printing, DLP high-precision printing with red wax, rapid customization of prototype models, and prototype replication, among others.

Utilizing advanced SLA rapid prototyping, German red wax machine printing, and high-precision American machine printing, Opro-tech uses light-sensitive resin materials with superior performance, similar to commonly used ABS materials, featuring waterproof, durable, high strength, and heat resistance.

By utilizing 3D printers for production, Opro-tech takes advantage of high-speed, high-precision printing for large-sized items, regardless of complexity, providing integrated manufacturing.

At Opro-tech, we offer a wide range of 3D printing services for customized prototype models and post-processing, including prototypes, model molds, shoe molds, medical, graduation art design, sandbox model customization, 3D printer action figures, crafts, jewelry, automotive manufacturing, 3D printed portraits, figurines, and 3D printed gifts, among others.

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