CNC machining stands for "computer numerical control" machining. It is a relatively new process in the world of machining which allows for increased efficiency through higher levels of automation and by allowing the machine and it's computer controls to do all the work. While CNC machines are expensive and complicated, they quickly pay for themselves by reducing the workload and preventing errors.

The first major advantage of CNC machining is that it improves automation, removing the need of an operator for all but a few parts of the work. CNC machines can be left unattended for hours or even days if necessary, allowing operators to focus on other tasks. This also allows for a company to retain fewer operators, thereby saving on overhead. By removing the operator, safety is also increased, since should there be a jam or other potentially dangerous machining error, the operator will not be holding the tool and the only thing damaged will be the tool itself. CNC machines can also work much faster than human machinists, since they are faster, stronger, and do not need to take breaks. They can also be run late at night, when most of the workers have gone home, since machines do not need to worry about being sleepy or getting paid overtime.

The second big advantage to CNC machining is that it produces an exact result every single time. Even the best human operator will have minor variations between finished results, whereas a CNC machine will produce exactly the same result each and every time it is run. This is very important in the modern world of standardized and interchangeable parts, where a single defective cut can make an entire machine wholly unusable. All that is necessary is for a single program to be developed and placed into the machine. Then the machine can toil away at however many work pieces are needed, producing an exact replica down to thousandths of an inch each and every time.

The third big advantage to CNC machining is the flexibility of the machine itself. While humans are much more flexible and trainable than machines, a CNC machine can be completely reprogrammed in a matter of hours to produce a completely different product. It is thus possible to refer back to old programs or install new programs when a different work piece is required. This gives CNC machines a big advantage over other machines, since they can quickly shift to producing a completely different product without the installation of many new parts or a major overhaul of key components. This also ensures that CNC machines can keep up with customer demand, since they can very quickly shift from making a part that is in surplus to a part that is lacking should a need arise.

To learn more, check out this great resource for CNC Machining.

Whatever the item a person or a company intends to produce, creating a prototype is a crucial step in the design process that cannot be glossed over. Why is prototyping important? There are several main reasons; testing and evaluating the design, clarifying production issues and costs, selling it to others, as well as making clear any patentable details. 


Evaluating and Testing the Design

Unfortunately, ideas and drawings of a design can sometimes be a far cry from the real world in which the product will be used. By creating a prototype it is possible to sit down with a real version of the product and determine which aspects are worthwhile and which parts need to be revised, changed, or discarded. In the process, it may be possible to find glaring omissions that, on paper, weren't noticeable.

Additionally, creating a prototype will allow the design team to not only evaluate, but also test the product before going into full production. Imagine ordering tens of thousands of units, only to discover one part isn't as strong as it needs to be. If corporate giants can make mistakes, it is all the more important for smaller companies to not forget the importance of prototyping before beginning production. 


Clarifying Production Costs and Issues

Once production begins, it is costly and time consuming to make changes. By prototyping before production begins, it is possible to take a glimpse at the production process and see if any steps can be changed, combined, or even removed. This not only streamlines production, but keeps the cost of the actual production to a minimum. Subsequently, if there are any difficulties in production or perhaps processes that can create problems for the final product, it is much better to see these before production starts. It can also help the design team ascertain the optimal method for production; injection-molding, silicone molds, stamped metal, etc.


Selling the Product to Others

Just like it is far easier to see if there are any problems with a design by holding an actual working model, it is also far easier to sell to potential customers when they have a prototype to hold and manipulate at a marketing presentation. Without a prototype it's only a concept. It can be difficult to get a client to commit to a purchase of a concept. With a prototype in hand, the concept instantly becomes real and it is far easier to sign a purchase order.

The customer needs to be taken into consideration during the prototype phase as well. No matter how great the designers and testers think a prototype may be, real consumers may not like certain aspects of it. If the end customer doesn't like it, they won't buy it, which is why focus groups and external testing with prototypes needs to be addressed before production begins.


Patents

If a product is new enough or unique enough, patents need to be considered. It's no use to design and manufacture a great product only to have another company start producing a remarkably similar product because the original company failed to patent key aspects of the design. By having a working prototype, it is much easier to sit down with a patent attorney and see what design aspect may be patentable. On the reverse side, it is possible to see what parts of the prototype and design violate patents of other individuals and how they can be changed before production, and the chance of a lawsuit, begins.

Contact Schmit Prototypes today and get a high quality prototype fast! 715 235-8474.

Stereolithography (SLA) is an additive process that uses a vat of liquid UV-curable photopolymer resin and a computer controlled UV laser to build parts one thin layer at a time. The UV laser cures, or, solidifies the part layer and adheres it to each additional layer.

After each layer has been cured, the SLA machine lowers the platform by a single layer thickness, typically 0.002" to 0.006". A resin filled sweeper blade then moves across the cured layer recoating it with another layer of uncured resin. Each layer is cured by the laser, curing it and adhering it to the previous layer. This process repeats until the 3-D part is completed. Once complete, the SLA machine raises the platform from the vat of resin and the part can be removed, cleaned and final cured in a UV "oven".

One advantage of stereolithography is that a functional part can be built in a relatively short period of time. The amount of time required depends on the size, complexity and layer thickness the part will be built with. Parts can take anywhere from a few short hours to a day or more. Parts built with an SLA machine can be used as master patterns for RTV molding, finished and painted or simply lightly sanded and may be used for shape studies or final presentation models.

The Stereolithography process can help you decrease costly mistakes by detecting design flaws before the manufacturing process. It can be a cost-effective option for low-volume production and also provides quick lead times.

To learn more, check out this great resource for Stereolithography.

RTV molds are created using a master pattern. The master pattern can either be created using CNC machining or a 3D printer, such as an SLA machine. Silicone rubber is poured around the master pattern, creating a cavity and a core. The master is removed once the silicone rubber sets and leaves a void into which several materials may be cast.

RTV molding is an inexpensive way to bridge the gap between prototype and production. It is most effective when you need a short run of parts to simulate production parts. More common materials used for RTV molding are polyurethanes, wax and silicone. Polyurethane can simulate a wide range of materials from soft rubber to hard plastic.

Cast Urethane parts can produce incredible detail and excellent surface finish. Often times little finishing is required on cast Urethane parts because the details and textures are applied to the master pattern. Because of the flexibility of Silicone, reverse draft, inserts and undercuts are all easy to deal with.

Urethane casting can be used for several applications including visual models, product testing, color and texture studies and even low volume production. Urethane parts can be of nearly any size and shape and can also be color matched.

To learn more, check out this great resource for Urethane Casting and RTV Molding.

Have you been looking for an alternative to traditional steel molding? Are you interested in reducing cycle time and costs? Aluminum tooling may be the answer for you. Aluminum tooling has many benefits that make it a viable option these days. What are these benefits?

 1. Aluminum is easier to cut than steel which allows for faster machining and shorter lead times.

2. Although Aluminum is perceived to be too soft for high volume production, this is simply not    true. Some Aluminum molds are capable of producing parts after 2 million cycles! 
  
3. Aluminum cools at a much quicker and even rate than Steel. This reduces cycle time and saves money. 
  
4. Since Aluminum is so light it can be machined on smaller equipment and also at a faster pace. 
  
5. Aluminum dissipates heat at a very even rate, which allows for great dimensional stability due to less distortion. 
  
6. There is far less scrap because there is far less cracking and warping. 
  
Aluminum is often looked at as weak, soft material that is no good for high volume production. However, Aluminum can in fact be used for high volume. It can also be machined faster and dissipates heat at a much quicker, even rate than Steel does. As a result of this, often times lead times are shortened and money is saved. Who doesn't want to save money? 
  
As for the longevity of Aluminum tooling, surface coatings can extend the already impressive life cycle. Many companies are now using Aluminum for production instead of just prototype work.

Schmit Prototypes offers low-cost aluminum and steel tooling. Most of our inserts are created using Aluminum. Our in-house capabilities allow for aggressive lead times on tooling and a quick response to tool modifications.

Our knowledge of the benefits of Aluminum tooling has helped our customers save time and money. Give us a call today to find out if Aluminum tooling can do the same for you!