How To Choose The Right Machining Method For Small-Batch Parts?

DALIAN, China - April 27, 2025 - PRLog -- Key Considerations

Complexity of the Parts

If a part features intricate geometries, such as fine internal structures, irregular curved surfaces, or tiny features, traditional machining methods may struggle to meet the requirements. For instance, CNC machining is often a better choice for parts with complex internal flow channels. With precise programming control over tool movement, CNC machining enables the accurate processing of complex shapes. On the other hand, for simpler flat parts, more straightforward and efficient methods like stamping or laser cutting may be preferable.

Precision Requirements

Different machining methods offer varying levels of precision. For components requiring extremely high accuracy, such as those used in the aerospace industry, grinding or electrical discharge machining (EDM) may be the preferred options. Grinding can achieve micron-level precision, making it ideal for parts with strict surface roughness and dimensional accuracy requirements. EDM, on the other hand, is well-suited for processing complex-shaped parts made of hard materials, as it removes material through electrical discharge, ensuring high precision. For general mechanical components with lower precision demands, conventional machining methods like turning and milling are usually sufficient.

Material Characteristics

The choice of machining method is greatly influenced by the material of the part. For example, when working with extremely hard materials like carbide, traditional cutting processes may be highly challenging. In such cases, non-traditional machining techniques like EDM or laser machining are more suitable. Laser machining uses a high-energy-density laser beam to instantly melt or vaporize the material, enabling efficient processing of hard-to-machine materials. Conversely, for softer materials such as aluminum alloys, machining methods like turning, milling, and stamping can be effectively applied with high efficiency. Additionally, some materials may deform or crack during machining, requiring careful selection of processing parameters and methods to prevent defects.

Cost Considerations

In small-batch production, cost is a critical factor. Tooling costs can be a significant portion of the overall manufacturing expense. For small-batch parts, using machining methods that require expensive molds—such as injection molding—can lead to a very high per-unit cost. In such cases, it is more economical to choose processes that do not require molds or have lower tooling costs, such as 3D printing or CNC machining. 3D printing builds parts layer by layer without the need for molds, making it a cost-effective choice for low-volume and customized production.
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