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With over ten years of experience in high-mix, low-volume CNC manufacturing, we’ve developed proven strategies to improve part machinability. Thoughtful design not only simplifies tooling but also leads to faster lead times, greater dimensional accuracy, and more consistent quality.
1. Ensure Adequate Tool Clearance
Avoid placing holes or features too close to adjacent walls, as this restricts tool access. For instance, when a hole is too near a vertical surface, a long, custom tool may be required, compromising rigidity and precision. By increasing spacing in the design, standard tooling can be used, which enhances accuracy and process reliability.
2. Include Undercuts for Gear Shaping
To enable effective gear hobbing or shaping, particularly for small and large gears within the same part, undercuts must be incorporated. These allow full tool engagement without interference, improving form accuracy and reducing tool stress.
3. Provide Space for Tool Retraction in Planing
When designing for planing operations, ensure that there is adequate clearance at the beginning and end of the cut path. This enables smooth tool retraction and movement, preventing tool marks and mechanical binding.
4. Preserve Grinding Undercuts at Transitions
In grinding operations, maintaining undercuts in transitional areas between surfaces helps the grinding tool move freely. This is especially important for internal corners, where tool radius limitations can otherwise lead to incomplete surface finishing.