| 1 |
Match the material to the part function Define load, temperature, corrosion, wear, and weight requirements before requesting a quotation. |
Aluminum alloys for low weight and corrosion resistance; carbon steel for strength; stainless steel for corrosion resistance; engineering plastics for electrical insulation and low friction. |
Use general dimensional tolerances for non-critical features and reserve tighter tolerances for functional interfaces. |
3-axis or 5-axis milling; CNC turning for round components. |
Material grade, condition, and certification should be stated clearly because strength and machinability can vary within the same material family. |
| 2 |
Specify only the tolerances that matter Overly tight tolerances increase machining time, inspection effort, and cost. |
Common metals and plastics can usually be produced economically with standard shop tolerances when the design permits. |
Typical general CNC capability is approximately ±0.10 mm; tighter requirements such as ±0.02–0.05 mm should be limited to critical features and confirmed in advance. |
Precision milling, turning, grinding, or finish boring where required. |
Identify datums, critical dimensions, geometric tolerances, and measurement temperature in the drawing or specification. |
| 3 |
Choose the process according to part geometry Process selection affects accuracy, surface finish, setup count, and production cost. |
Most machinable metals and rigid engineering plastics are suitable for subtractive CNC processes. |
Turning is generally efficient for concentric diameters; milling is preferred for prismatic features and angled surfaces. |
CNC turning for shafts and bushings; CNC milling for pockets, holes, slots, and profiles; Swiss-type turning for small slender parts. |
Provide the 3D model and 2D drawing so the manufacturer can evaluate fixturing, tool access, and workholding. |
| 4 |
Design for tool access Deep narrow pockets, sharp internal corners, and obstructed features often require special tooling or multiple setups. |
Aluminum is generally easier to machine in deep pockets; tougher steels and stainless steels may require slower cutting conditions. |
Maintain achievable tolerances at the bottom and sides of pockets; avoid applying the same tight tolerance to every feature. |
3-axis milling for open features; 4-axis or 5-axis milling for multi-face access and reduced repositioning. |
Use internal corner radii that are compatible with standard end mills. A radius is normally more economical than a sharp internal corner. |
| 5 |
Control wall thickness and slender features Thin walls and long unsupported sections are more vulnerable to vibration, distortion, and deformation. |
Aluminum and plastics may deflect more easily; steel can provide greater rigidity but may require more cutting force. |
Relax non-critical tolerances on thin sections and confirm the minimum practical wall thickness with the machinist. |
Light-pass milling, adaptive roughing, turning with appropriate support, and staged machining. |
Consider ribs, temporary support, shorter tool overhang, and multiple roughing or finishing operations when stability is limited. |
| 6 |
Plan holes and threads for standard tooling Standard drill sizes, thread forms, and accessible hole locations reduce tooling and inspection costs. |
Aluminum, steel, stainless steel, brass, and many rigid plastics can be drilled and tapped with process-specific tooling. |
Specify hole position, diameter, depth, thread class, and whether the hole is through or blind; avoid unnecessary custom thread requirements. |
CNC drilling, tapping, thread milling, boring, and reaming for higher accuracy. |
Allow chip evacuation and tool clearance. Deep blind holes may require special strategies and can cost more than through holes. |
| 7 |
Define surface-finish requirements realistically Surface finish should be linked to sealing, sliding, appearance, or fatigue requirements. |
Machined aluminum and steel commonly receive a visible tool-marked finish; stainless steel and plastics require material-specific finishing controls. |
Typical machined surfaces may be around Ra 1.6–3.2 µm, while finer finishes require additional passes or finishing processes. |
Fine milling or turning; polishing, honing, lapping, or grinding when lower roughness is functionally necessary. |
State the required Ra value, measurement direction, and location. Do not use “smooth finish” without a measurable specification. |
| 8 |
Account for heat treatment and finishing Secondary processes can change dimensions, hardness, corrosion resistance, and appearance. |
Heat-treated alloy steels for strength; anodized aluminum for surface protection; stainless steel with passivation for improved corrosion resistance. |
Define whether dimensions apply before or after heat treatment, coating, plating, or anodizing, including any expected coating thickness. |
CNC machining followed by heat treatment, coating, plating, passivation, or other specified finishing. |
Protect datum surfaces and masking areas. Final inspection should occur after all dimensional finishing operations. |
| 9 |
Use a clear inspection and measurement plan Inspection requirements should be agreed before production rather than after delivery. |
All materials can require dimensional, visual, hardness, or material verification depending on the application. |
Use GD&T or clearly defined plus/minus tolerances for critical characteristics; identify sampling level for production batches. |
CMM inspection, calibrated gauges, micrometers, height gauges, optical measurement, and surface-roughness testing as appropriate. |
Request a first-article report or inspection report when risk is high. Measurement equipment should be calibrated and traceable. |
| 10 |
Balance prototype speed with production economics A design that works for one prototype may not be the most efficient choice for a repeat order. |
Aluminum and plastics are often practical for prototypes; steel, stainless steel, brass, and production-grade plastics may suit longer service life or larger batches. |
Use prototype tolerances that validate the function, then tighten or standardize production tolerances only where test results require it. |
Rapid CNC milling or turning for prototypes; multi-axis machining, optimized workholding, and repeatable tooling for production. |
Share expected annual volume, batch size, delivery target, packaging needs, and revision-control requirements to support an accurate quotation. |