How much does CNC cost?

Computer-controlled cutting machine

Large 5-axis moving table CNC router Drawing of a Tabletop DIY - CNC router. Silver: Iron, Red: Stepper Motors, Light Brown: MDF, Dark Brown: Hard Wood

A computer numerical control (CNC) router is a computer-controlled cutting machine which typically mounts a hand-held router as a spindle which is used for cutting various materials, such as wood, composites, metals, plastics, glass, and foams. CNC routers can perform the tasks of many carpentry shop machines such as the panel saw, the spindle moulder, and the boring machine. They can also cut joinery such as mortises and tenons.

A CNC router is very similar in concept to a CNC milling machine. Instead of routing by hand, tool paths are controlled via computer numerical control. The CNC router is one of many kinds of tools that have CNC variants.

CNC Dynamics Pattern Maker

Applications

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A CNC router can be used to produce items such as door carvings, interior and exterior decorations, wood panels, sign boards, wooden frames, moldings, musical instruments, furniture. In addition, they see use in industry in the thermoforming of plastics by automating the trimming process. CNC routers can help ensure part repeatability and sufficiently efficient output for production, or allow one-off designs to be made.

Use

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Control panel for a large DMS 5-axis CNC router

CNC routers are controlled by a computer. Coordinates are uploaded into the machine controller from a separate program. CNC router are often used with two software applications—one to make designs (CAD) and another to translate those designs into a G-code or M-code program of instructions for the machine (CAM) in vertical, horizontal and perpendicular coordinates. As with CNC milling machines, CNC routers can be controlled directly by manual programming, but CAD/CAM allows wider possibilities for contouring, speeding up the programming process and in some cases creating programs whose manual programming would be impractical. On some controllers the G-code can be loaded as a vector file on the router control panel. A vector file can be created from a picture file by using a drawing (CAD) software.

The human operator selects the machine tool (such as a 1⁄4-inch (6-MM) v-bit or a 3⁄4-inch core box bit), speed, cut depth and tool path. For cut path, most machines give the options of tracing the vectors, cutting outside the vectors, or cutting inside the vectors. The operator determines the center point of the part, clamps the part onto the table, moves the bit directly above the marked center and down to the face of the part, and marks this as the starting point. The operator moves the bit up a few inches and selects the run G-code function. The machine begins to cut the design.

Computer-aided manufacturing

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CAM software makes the CAD drawing/design into a code called G-code. The illustration shows what a bare-bones CNC machine might look like without its computer controller.

Sizes and configurations

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CNC routers come in many configurations, from small home-style D.I.Y. "desktop", to large industrial routers manufactured for commercial use. CNC routers are used in sign shops, cabinet making, aerospace and boat-making.

Although there are many configurations, most CNC routers have a few specific parts: a dedicated CNC controller, one or more spindle motors, servo motors or stepper motors, servo amplifiers, AC inverter frequency drives, linear guides, ball screws and a workspace bed or table.

In addition, CNC routers may have accessories such as vacuum pumps, with grid table tops or t-slot hold down fixtures to hold the parts in place for cutting. CNC routers are typically available in 3-axis and 5-axis CNC formats. Many manufacturers offer A and B axis for full 5-axis capabilities and rotary 4th axis. Common industrial CNC router sizes include 4 × 8 feet and 5 × 10 feet.

Many CNC routers today are made of aluminum extrusion which provide great flexibility as this can be shipped from almost anywhere unassembled but also provides size options. Some popular extrusion used are MakerSlide, V-Slot linear rail, and 8020 T-Slotted profile.

Materials

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Wood

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A typical CNC wood router

A CNC wood router is a computer-controlled router tool that carves/etches objects or images into the face of a piece of wood.[1] The CNC Router is ideal for hobbies, engineering prototyping, product development, art, and production works. The CNC works on the Cartesian coordinate system (X, Y, Z) for 3D motion control; however, typical CNC operated systems can only make carvings on flat planes. The machine sits on a track and is not capable of making round or spherical cuts. Parts of a project can be designed in the computer with a CAD/CAM program, and then cut automatically using a router or other cutters to produce a finished part. In some instances, the table will not come with a router included. This allows the user to change out routers for different applications. For lighter strained cuts, they could use a lower grade router but for more intensive applications.

Metal

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Milling is the machining process of using rotary cutters to remove material from a workpiece advancing (or feeding) in a direction at an angle with the axis of the tool. It covers a wide variety of operations and machines, on scales from small individual parts to large, heavy-duty gang milling operations. It is one of the most commonly used processes in industry and machine shops today for machining parts to precise sizes and shapes.

Stone

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A stone CNC router is a type of CNC router machine designed for marble, granite, artificial stone, tombstone, ceramic tiles, glass machining, polishing for arts and crafts, etc. Wood, metal and stone require different "bits" or "inserts". There is bit call as diamond tools with different diameter 4mm, 6mm, 8mm mainly used. For wood CNC-ing, bits with sharp cutting edges are used, while for Stone CNC-ing, the bits are made of a metal bar with a sintered layer of extremely hard but roughly shaped particles. Routing CNC is more like grinding than cutting.

Because stone dust is very abrasive, these routers also have much better protection for the guide rails (below cover). With "wood" routers the guide rails are often visible from the outside & unprotected, while stone routers are fully covered.

Stone routers also have a water recirculation system. A small jet of water is pointed at the router bit and this captures almost all fine stone dust in the water, which then flows to a collection reservoir where the stone particles settle on the bottom.

Polyurethane foam

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Polyurethane foam can also be cut using a CNC router in order to produce complex shapes which would otherwise be difficult or impossible to replicate by hand. Depending on the type of foam being converted, a CNC router would be able to cut through up to an 8lb density. By converting a CAD design file into a CAM file, the CNC Router is able to read relevant information and produce a highly accurate finished product.

References

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Reducing costs in production can help you continue to quote competitive prices, even amid industry challenges such as rising inflation, increasing labor costs and other economic concerns. It can ensure you get the best margin for the work you perform or may create opportunities to pass on savings and strengthen customer relationships. Importantly, many of the measures to reduce job costs will also make your processes more efficient and improve your resource management overall. 

Automate Inefficient Processes and Operations

 

Automating processes in your CNC machining center, such as deburring and finishing, will reduce overhead and labor costs, as well as QA time and scrap. Automating deburring and finishing with Xebec ceramic fiber brushes improves operations and timing as these brushes:  

• Perform like cutting tools

   

• Achieve consistent performance

   

• Deburr and finish in one step

   

• Achieve a finely finished surface

   

• Do not deform after repeated use

   

• Have incredible grinding power

   

Learn how Xebec ceramic fiber brushes perform like a cutting tool. >> 

Change Part Material (If Possible and Reliable)

 

If you have influence over part material, changing the type can reduce costs. Certain materials are more expensive and difficult to machine versus others, taking more time, money and effort. Most materials generate burrs during production, whether from milling, drilling, cutting or otherwise. Understanding how different materials behave in the deburring process and which tools will best achieve the precision and quality you need can help you make profitable choices around material type, keeping in mind that parts must be able to reliably perform their end function.  

Improve CNC Machine Capabilities

 

When you assess the entire process, you may find that you need more capability out of your CNC machine. Many machines can be retrofitted so they’re able to work more complex parts, faster. For example, our application experts have experience integrating Xebec ceramic fiber brushes into a variety of CNC machine types.  

In some cases, you may want to add a five-axis machine to your facility. The upfront investment of a five-axis machine is hefty, but the functionality you get with it will quickly return the investment. 

Optimize Processing Conditions

 

The tools used and the shape they’re in affects the number and severity of burrs you’ll have to remove. You can save time and money by controlling burr formation in processing. The more finished a piece can be when it’s removed from the CNC, the faster the part can be inspected, packed up and shipped to the customer. When milling, the angle and rotational direction used as well as the depth of cut and feed rate will affect the quality as well. Sometimes, a simple change in the order of operation can significantly improve the quality of the machined piece. Using Xebec’s team and solutions to help you move faster from CNC to shipping.  

Optimize Production Processes

 

Getting visibility into your processes can help you identify the most efficient – and least efficient – activities. For instance, you can identify which lot sizes are optimal for productivity. Consider whether certain levels of custom fixturing are not worth accepting a job. You can use this understanding to inform conversations with potential customers, as you can suggest increasing the job size if it makes the cost more worthwhile.  

If you’re tapping parts in the CNC, it’s a good time to consider an investment in a rugged tapping arm, like one from Roscamat’s line of electric and pneumatic arms. By placing a Roscamat tapping arm outside your CNC, your operation can reduce cycle time and gain a significant improvement in speed, accuracy and productivity. While the CNC is milling the next part, the operator can tap the holes in the last part. 

Learn how to cut CNC milling time with Roscamat tapping arms. >> 

Look at the Big Picture

 

Consider all the steps involved in a machining job, from CNC programming and loading/changing tools to deburring, finishing, QA and shipping. Calculate how much each step requires and costs in labor and overhead and determine the ROI for the whole job.  

Cutting out a significant chunk of manual labor in the deburring and finishing process can save your organization thousands of dollars a year and help deal with the lack of skilled labor. Automating your deburring and finishing process in your CNC provides a positive ROI and impacts your company in many ways by reducing these costs: 

• Extra cost of CNC operators

  having to stop work to deburr parts. Operator labor has a higher cost, especially when engineers are recruited into the deburring efforts.

   

• Lost production time

  when not operating the CNC machine, wasting machine value and missing revenue opportunities.

   

• Cost of returned parts

  because of unreliable quality due to exhausted, injured or low-skilled employees deburring.

   

• Cost of purchasing and constantly replacing consumables

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• Cost of injuries and accidents

  due to fatigue.

   

• Additional expenses such as transportation costs for outsourced work.

   

Understanding all the factors involved in the entire machining job will help you develop a good CNC machining cost calculator and improve processes overall. Streamlining the deburring and finishing process with Xebec solutions will not only reduce costs but help you provide consistently high-quality parts and give you the excellent reputation you deserve.  

Be Your Company’s Hero: Make the Case for Modern Deburring. >>