Custom Made CNC Milled Parts 4 Axis 5 Axis For Medical Devices

Custom Made 4-Axis 5-Axis Aluminium CNC Milling Parts For Medical Devices

CNC milling involves cutting a workpiece using computerized and multipoint cutting tools. Known for its accuracy and precision, the process is an integral part of several industries, most notable being automotive and aeronautics.
This article explains everything you need to know about the CNC milling process before choosing it for your project.

What is CNC Milling?

CNC milling is a subtractive manufacturing process that combines traditional milling with computer numerical control (CNC) technology. It involves using a rotating cutting tool to remove material from a solid block of metal, plastic, wood, or other materials to create precise parts and products. Unlike manual milling, where operators control the machine by hand, CNC milling is fully automated. The machine’s movements are guided by pre-programmed G-code, which dictates toolpath, speed, and cutting depth, ensuring consistent and highly accurate results.
There are various types of CNC milling machines, ranging from simple 3-axis machines to more complex 5-axis models that allow for greater precision and the creation of intricate parts. CNC milled parts have high tolerance as milling machines can achieve a tolerance between +/- 0.001 in. to +/- 0.005 in (some machines can achieve a tolerance of +/- 0.0005 in).
CNC milling is widely used in industries such as aerospace, automotive, and electronics due to its ability to produce complex, high-quality components with minimal human intervention. By utilizing CAM (Computer-Aided Manufacturing) software, design files are translated into G-code, making the entire process streamlined and highly efficient.

How Does CNC Milling Work?

Alongside CNC drilling and turning, CNC milling forms the bedrock of the CNC machining process. However, it has a unique mechanism compared to the others.
The process works by removing parts from a workpiece using a computer-controlled rotating cylindrical cutting tool that rotates and moves along multiple axes.
CNC milling can be broken down into three significant steps:

Step 1: Prepare a 2D or 3D CAD Model

Use CAD/CAM software such as Autodesk Inventor or SolidWorks to create a machinable 2D/3D drawing of the final product.
Preparing a CAD file for CNC machining depends on your software. On the one hand, some software can convert 2D images into 3D CAD files. On the other hand, some software allows you to trace a 2D image to convert it into a 3D file.
There is also a technical drawing given to the operator containing info such as:
Critical features/dimensions of a part
Tolerances
Indication of threads
Finishing preferences
Construction lines

Step 2: Export Your Design to a CNC-Compatible File Format

The CNC milling machine won’t understand the model you design unless it is in a compatible CNC machining file format. Therefore, it’s necessary to export your CAD model into CNC-compatible file formats with the CAD/CAM software. Examples of such formats are STEP and STL.
If the software cannot convert the design to such a format, you can use several online services such as Cadexchanger and Convert.emachineshop.com.
On converting, the file will direct the machine on the rotational and linear movement, cutting sequence, toolpath, machine, and workpiece speed associated with the process.

Step 3: Set Up a CNC Milling Machine and Operate a CNC Mill

The operator will attach the cutting tools to the spindle and place the workpiece on the table. They will then set up the machine to initiate the machining program and begin milling.

Advantages and Disadvantages of CNC Milling in the Production Process
The process is an important part of many industrial production processes due to its advantages. Nevertheless, it also has its disadvantages. Below are a few advantages and disadvantages of the process.

Accuracy and Precision

CNC milling machines have higher accuracy and precision. Therefore, they can create parts according to their technical specification. As a result, they can mill parts with tolerances as tight as 0.0004. Also, being an automated process reduces the chances of human errors.

Fast and Efficient

CNC millers offer fast, high-efficiency operation compared to conventional millers, largely due to their ability to hold multiple cutting tools through an automatic tool changer (ATC). Once a design is programmed, these machines can operate continuously with minimal human supervision, maximizing productivity and resource efficiency—especially valuable for large-scale projects.

Large Compatible Material

The process is compatible with many compatible materials, e.g., plastic, composites, and metals. Therefore, CNC milling might be the perfect process once you have a block of material.

Broad Design Capabilities

CNC milling can accommodate a vast range of designs, from straightforward shapes to intricate three-dimensional forms. Its advanced multi-axis operation allows for the creation of complex geometries that would be challenging or impossible to achieve with conventional machining methods.

Material Versatility

This milling process is adaptable to a wide variety of materials, including metals, plastics, glass, wood, and stone. Such versatility enables manufacturers to select the most appropriate material for their specific applications, enhancing overall product quality.

Applications of CNC Milling
Milling is highly accurate, precise, and with high tolerance. Hence it has a wide range of applications. Below are some of its industrial applications.
Aerospace
Computer numerical control milling is applicable in making many aeronautic components using materials such as Titanium and Aluminum. These materials are lightweight and durable. Due to the high need for accuracy and precision, the process is considered suitable.
Automotive
The automotive industry uses milling machining due to the requirement for efficiency without losing accuracy. Therefore, it is suitable for products made using the process including interior panels, cylinder heads, drive axles, suspension components, exhaust parts, and gearboxes.
Agriculture
CNC milling machining is suitable for making general-purpose parts and components such as gears and shafts, nuts and bolts, and flanges. Furthermore, it is suitable for both large-scale and short-term production capabilities.
Medical
Medical parts such as prostheses require precise and unique designs. Therefore, CNC milling is the better method for such parts. The design is retained, and there is productivity and efficiency.

CNC Machining Tolerance:

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