What Green Manufacturing Can Expect From CNC Machining in the Future

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Green businesses are looking for more sustainable manufacturing solutions.  There are a number of ways that manufacturing can be changed to produce a lower carbon footprint including the switch to CNC machining.  One of the biggest reason that CNC machining is greener is because it can be done electronically.  Customers can send electronic files to the factories so there will be no travel to the site therefore, reducing carbon emissions from driving. 

CNC Machining Is the Key to Sustainability in 2020

Modern manufacturing and production is changing rapidly.  The growth of industries using the CNC machine is aiding this change.  The CNC (Computer Numerical Control) machine was first introduced in the 1940s and changed the manufacturing game to what we see today.  CNC Machines make it possible to scale any given manufacturing process without losing any quality or accuracy during production.  As computers have become more mainstream, CNC machining has become essential in the manufacturing industry. 

One of the benefits of using a CNC machine is improved efficiency.  One of the biggest reasons CNC machining lowers emissions is by reducing transportation, while reducing material waste and machining time. 

CNC machines rely on Computer-Aided Design (CAD) files to create prototype parts.  Every part of the process is controlled by a computer and are technical and highly automated products. Old industrial equipment such as routers, drills and lathes are driven by computer programs and achieve a precise level of control.  This simplifies the whole manufacturing process and is widely used in many different industries. 

Over the past few years there have been a number of changes with CNC products.  CNC machining is becoming more affordable.  The barrier of entry into the CNC machining industry is lower than ever.  Manufacturing companies now offer a diverse range of services including prototype manufacturing and prototype machining. 

Many companies have started to adapt to use The Internet of Things, a system of interrelated computing devices, mechanical and digital machines that has the ability to transfer data over a network without requiring human to human or human to computer interaction.  This encourages collaboration which leads to the development of a higher quality product.  Machines are also now connected to computers or mobile devices.  CAD files can be transmitted electronically and you can now send designs for injection molding services and rapid machining.  Automation can help create new jobs in this industry for technicians and programmers.   

As technology has evolved, the manufacturing process of these machines have too.  CNC machines have become smaller and more compact and now companies have decided tp use smaller portable devices rather than big, immobile machines.  As the demand for CNC machinery made products increases, so does the need for CNC machines to operate at optimum levels.  Coders and developers will need to simplify the user interface of the machinery to make them more user friendly. 

Companies that offer CNC services are continuously working on tightening their tolerances and quality control systems.  Orders are being produced of any quantity, by using a wide range of materials at affordable prices while still remain the highest quality possible. 

At Sheldon Precision we have learned to adapt and follow current trends, as technology is constantly changing and evolving.  Contact us today for a custom quote https://sheldonprecision.com/request-a-quote/

Article Adapted from: https://blueandgreentomorrow.com/features/what-green-businesses-can-expect-from-cnc-machining-in-future/

How Precision Machining Has Become Beneficial in Manufacturing Medical Devices

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Precision machining is used in many industries including electronics, aerospace and medical.  Many medical parts and devices are manufactured by using CNC machines.  The medical device industry is made up of different medical parts including implants for reconstructing spines and for hip and knee replacements.  

You count on your medical parts to be manufactured with accuracy and precision and ultimately safe for use in your body.  Precision machining helps create the exact dimensions and sizes for the surgical tools that will be used to administer these medical parts.   Machining is also used to create the complex parts for lasers and robotics now used in surgeries.  Using these machines will create more innovations that will lead to future medical advances.  These tools require extremely small and precise parts that only CNC machining tools can make.  

These tools are used for the finest surgeries including on your heart or brain so they should be accurate, reliable and safe while they are being produced.  The materials for use in the medical world need to meet strict standards for durability, safety and non-reactiveness with the human body and the ability to be sterilized.  Precision machining allows these materials to be skillfully transformed into the detailed shapes and sizes needed for specific medical applications and devices.  Many of these pieces are permanently implanted into people and need to be smooth and tight to eliminate any reactions in your body such as being rigid and scratching.   CNC precision machines are ideal for making these parts ensuring that every part is identical and fits together for optimum function.  

Insulin pumps, heart monitors and defibrillators are medical implants that save lives every day.  As medical parts have evolved and machines have advanced, over time medical designs have been become smaller and more precise.  This includes the casing and cables for these parts.  The implants can now be placed inside the body, allowing those people who need these implants to be able to live a normal life.   

Precision machining allows certain medical devices to be custom designed for a more personalized fit.  This is extremely important for prosthetics such as artificial limbs, knees and implants like defibrillators which needs to fit each person’s needs.  Precision machining is used to create and design custom parts along with being cost effective.  Designs are inputted to the computer controls and parts can be quickly and accurately made for small or larger runs.  

Precision machining has contributed so much to advance in the medical industry and will continue to evolve and be an important part of this industry moving forward.  The medical industry counts on Sheldon Precision for our expertise, quality and attention to detail. Contact us today for a custom quote at https://sheldonprecision.com/request-a-quote/

Industries Using Precision CNC Machinery

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Computer Numerical Control (CNC) Machining creates numerous detailed parts required in dozens of industries.  Many industries require custom-created parts for specific uses rather than mass production.  The ability to accurately design and create pieces with a computer is the key factor many companies are looking for.  Industries including the medical field, transportation, the military and more rely on machining parts.  Since the technology that makes up computers and machines advances daily, this allows for more intricate and customized designs to be achieved.  

Precision is what is needed in the medical, aerospace, electronics and other industries.  If any of these parts are not manufactured with a high degree of precision and held to tight tolerances, serious product defects could result 

Machining uses many different devices such as milling, Swiss screw machining and machine turning.  The machine operators choose the best method to use based on the required precision of the product and content used. 

  • Machine turning – like a lathe, CNC milling machines turn the material but a computer controls the entire process.  This makes mass production of parts possible 
  • Swiss Screw machining – requires an expert for set up and needs extra time but produces the most precise parts within 0.005 inches 
  • Machine milling – turns the tools around the piece and the mills can use numerous tools for highly detailed parts.  

By using the right machine and material for the job, CNC machinists can serve in a wide range of industries.  Each of these industries have their own needs which means that all of the different options that can be used in CNC machining will be not necessary for every business.  

Medical Industry 

The medical industry relies on customized products to fit the many needs of their patients.  Many devices used in the medical field are disposable to protect patients from infectious disease.  Businesses in this field require precision and high volume parts to fulfill the needs of their facilities.  Sometimes the companies may request prototypes of the product before requesting a full run especially if they are testing out new ideas.  CNC machines adapt well in the medical field due to the variety of materials and devices available.  Here are some of the parts that can be created by CNC machining: 

  • Implants 
  • Orthotic devices and screws
  • Electronic enclosures for monitoring devices 
  • Research equipment 
  • Shielded enclosures 
  • MRI Machines 
  • Electrical parts 
  • Customized packaging to maintain sterility 
  • FDA approved production 
  • Pieces made from high temperature plastics 
  • Medical instruments 

These machines include the rapid creation of customized parts and manufacturing done in an environment approved by the FDA.  When making individual designs, the computer allows the engineers to see the piece in 3D before machining it.  This ensures every part has the exact dimensions required.  These parts must have the smallest possible margin of error to avoid medical misdiagnoses and part malfunctioning.  Our ability to manufacture to tight tolerance with consistency coupled with superior quality control has set Sheldon Precision apart from competition within the medical industry.  

Aerospace Industry

High speeds, fast air currents and extreme pressure are three conditions devices in the aerospace industry encounter on a daily basis.  To avoid damage to the aircraft, engineers muse precisely construct every component.  CNC machining for the aerospace and aviation industries must meet high precision requirements which often reach as tight as 0.0004 inches.  Machinists must create these tolerances with extra durable materials such as titanium, aluminum, nickel, alloys and plastics.  The materials used will depend on the parts created and properties desired from that component.  Parts made for the aerospace and aviation industry include many different components of aircraft and the devices that service them including: 

  • Manifolds 
  • Bushings
  • Airfoils 
  • Landing gear parts 
  • Electrical connectors 
  • Antennae 
  • Radio frequency suppression materials 

Without the ability to design and create multiple precisely made parts, the air and space industry may not have reached the technological level that it is at today.  CNC machining is ideal for manufacturing prototype parts.  By seeing the 3D image on a computer, the engineer can make quick changes to the design based on testing.  Once the design has been finalized, the CNC machining process for one or multiple parts can begin.  Similar to the military and defense industry, the aerospace industry has demanding standards.  Sheldon Precision utilizes modern CNC machining to produce accurate and reliable components use in many aerospace applications.  State of the art machinery and skilled operators turn our precise components in a variety of materials including aluminum and titanium. 

Military and Defense Industry

The military industry is similar to the petrochemical industry where they use parts that need to be rugged and durable for every environment and climate.  The military has strict regulations set forth by the government and the products produced need to adhere to these regulations.  The parts created for the military can be similar to those produced in the aviation, transportation, electronic, marine and medical industries.  Though the parts may be similar, they don’t have the needs of the defense sector to keep up with the latest technology and having parts that reliable in the most out of reach locations.  These parts can include: 

  • Communications components 
  • Electronics 
  • Transportation components 
  • Plane parts 

Due to the strict regulations and security measures, the exact products and procedures used for creating military equipment require secrecy.  CNC machining can create quick upgrades, long lasting parts, creation of parts from robust materials and mass output of approved parts that require tight tolerances.  If CNC machines are being used, regular testing and upgrades of the devices must be done to allow the technology to be the most up to date to help ensure the best protection for our country.  Accuracy, precision quality and dependability are indications of the components Sheldon Precision manufactures for the military and defense industry. 

Electronics Industry

CNC machining can be used to create both large and small parts such as the sizes needed in the electronics industry.  Some of these elements will require laser precision to produce the parts with fine accuracy up to 10 micrometers that may be required.  In addition to electronics and insulators commonly found in electrical devices, the electronics industry may also need communications components.  These parts can protect communications devices from electronic interference or create electrical connections between elements such as: 

  • Heat sinks
  • Amplifier housings 
  • Radio frequency interference shielding 
  • Electrical insulation 

The smaller the parts needed, the tighter the tolerances.  There is little room for error in the micro machining process.  By using a CNC machine, it increases the accuracy levels humans would not be able to achieve.  The electronics industry greatly benefits from this precise accuracy for components, housings and other parts.  Electronic, telecommunications and wireless products require precise components and smaller sizes.  Sheldon Precision has the experience and capability to manufacture a wide variety of components to any size and tolerance.

CNC machining can be used in a wide variety of industries and are able to create parts out of multiple types of materials.  If you are looking to use CNC machining for your products, contact us today for a custom quote at https://sheldonprecision.com/request-a-quote/ 

Swiss-Style Turning: The Prescription for Medical Parts Manufacturing

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Medical component manufacturing requires a machine flexible in its design that it can create any geometric shape that can be conceived.  Swiss-style lathes represent a key process for manufacturing many medical parts.  Bone screws are one type of medical component that uses Swiss machines.  This is due to the productivifty of the machines and ultimately being more cost-efficient for the manufacturer.  It is estimated around 95% of all bone screws are made on Swiss turning machines today.  This includes facial screws, dental implant screws and screws used to hold orthopedic bone plates in place. 

A Swiss-style lathe is known for its guide bushing and a sliding headstock.  The strength of the Swiss machining process is the material supported by the guide bushing.  Stationary tools cut the bar stock as it passes through the bushing.  One of the main advantages of this machine is its ability to cut components with large length-to-diameter ratios.  No taper is introduced to the part and the rigidity of the process significantly reduces or in some cases eliminates chatter.  Medical component manufacturers can use these machines for a wide variety of parts. 

It is common for Swiss lathes to have both sub-spindles and live tools.  The sub-spindle allows operations to be performed on the back side of the part, which is inaccessible from the main spindle.  Cycle times can be drastically reduced by allowing work that might otherwise be performed on the main spindle to be done simultaneously on the sub. 

Live tooling along with the Y axis, part of the gang tooling arrangement on Swiss machines and the C axis, which is standard on most machines, allows milling to be performed.  Live tooling on a lathe combines turning and milling, on workpieces where there are both turned and milled features, the component can have all operations performed in the same chucking.  This significantly reduces handling and improves the geometric location of the milled features to the turned features. 

Deep depths of cut are common with Swiss-style aches since turning must often be done to finish depth in one pass.  The deep cuts must be made with slow feed rates in order to reduce the power requirement; this combination produces long ribbons of unbroken chips that can wrap around the part and prevent coolant from reaching the cutting zone.  Over the past 10 years, high-pressure coolant has become a mainstay on many Swiss machines.  This coolant is a must to help control stringy chips when drilling deep holes.  High temperature alloys and titanium, which are common in medical components, require high-pressure coolant because of the high temperatures produced in the cut and by directing chips away from the cutting zone.

Medical components can be difficult to produce for a few different reasons:  materials and geometry.  Materials such as titanium, one of the primary materials for bone screws, and plastic have unique characteristics such as being poor heat conductors and producing stringy, difficult to break chips.  Complex geometries are also common with medical components, including high length-to-diameter ratios.  Swiss machines have a distinct advantage, there are other challenges such as bone screw designs evolving and the use of multi-start threads.  In multi-start threads, two or more threads start simultaneously and allow far more travel in one turn than single-start threads.  A double-start thread will advance twice as far per revolution as a single-start, triple-start thread three times, etc. Two-start threads are the most common but more frequently bone screw designs include three-start threads and some engineering requests are being made for four-start bone screws. 

The process of cutting double-start threads on a Swiss machine begins with insert design.  The insert design is two or more thread forms are ground on each insert.  The thread whirling process involves cutting the thread in one pass in order to take advantage of the support provided by the guide bushing.  Inserts for multiple-start threads must have the form for each start on the insert.  This can be a challenge for tool manufacturers because they must make thicker inserts to accommodate the additional forms.  For every additional start, the insert must be made thicker.  Multiple-start threads are cut with inserts that have the multiple forms ground into the insert.  Tooling manufacturers are striving to keep up with the advancements. 

Medical parts are often delicate which can create problems when they are picked off with the subspindle for backwork.  It is very important but difficult to apply just the right amount of pressure to hold the part in the subspindle.  Once the optimum gripping force is determined, it is not easy to communicate to other machine operators how the adjustment was made.  Another challenge is making dental implants because of their small size. 

Swiss-style machines have been combining turning and milling in one machine for a long time.  Now machine tool manufacturers have introduced laser options to be even more precise.  It will now be possible to make stents on Swiss machines due to the cutting of solid stock for the tubing.  This can be handy in prototyping because the inside diameter of the tubing can be bored out to that size to make small batches.  Swiss turning machines have evolved greatly from making small components in the watch industry to now being used in medical manufacturing. 

If you are looking to produce high quality parts for the medical industry contact us today and receive a custom quote at https://sheldonprecision.com/request-a-quote/

Article adapted from: https://www.sme.org/technologies/articles/2017/may/swiss-style-turning-rx-for-medical-parts-manufacturing/

How Swiss Screw Machines Work

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Screw machines are automated lathes which can machine turned parts.  The machine components spin very quickly on a rotating lathe, which shaves down metal to the size desired.  There are two types of screw machines: Turret and Swiss machine.  The Turret, also known as. Brown & Sharpe after its first manufacturer, mounts the workpiece on a vertical ram which works into the lathe.  The Swiss type, named after its place of origin and used by watchmakers for precision components, mounts the workpiece on a rotary slide. 

There are two main types of Swiss Screw Machines: automatic and CNC.  The automatic screw machine functions with a disc cam, which helps rotate the tools to the work piece bay.  A collet holds the workpiece in place, the disc cams move the tools in a radial motion and alter headstock positioning in order to account for any longitudinal discrepancies with the workpiece.  The automatic Swiss Screw Machine features very close spindle collets, which prevent much deflected debris from getting into the way. 

CNC Swiss Screw Machines, otherwise known as CNC turning machines or lathes, operate largely on the same principle as an automatic Swiss Screw machine, except that the operation is controlled by a CNC unit.  These turning machines can feature more sets of tooling, allowing for the machine to perform several operations on the same piece in a shorter amount of time due to the increased direction provided by the CNC.  Automatic Swiss Screw Machines can also perform several operations at once but it lacks the precision and swiftness of a CNC Machine.  A CNC Swiss Screw Machine can rotate a part at up to 10,000 RPM at an accuracy level of 0.0002 to 0.0005 inches.

The CNC Swiss Screw Machine and the automatic screw machine are cost-efficient for longer projects because once they are properly tooled and program-oriented, many machines can run under the supervision of one operator.  Preparation time can be up to an hour so shorter projects’ fixed costs might balance out for another tooling process but Swiss Screw Machines are able to do more precision work due to the tight collet, work-piece and tooling. 

Turret-type screw machines produce very similar results to Swiss Style Machines but the CNC Swiss Screw Machine can have more tooling fixtures applied leading to the possibility of a double spindle machine.  This feature cuts down on time and an operator since the part is automatically transferred from the screw machine to another machine for secondary operations.  Turret-style machines come equipped with a transfer attachment that can also perform this function. 

Both types of Swiss Style Screw Machines are found in the automotive, IT and consumer electronics industries.  Swiss Screw Machines were originally developed for Swiss watch production due to their accuracy and delicacy.  Since these machines have quick production times and low variable costs, Swiss Screw Machines can produce a large number of small, precision parts relatively quickly at low cost.  These machines can handle both exotic and common metals of varying strengths and composition they are widely applicable in many different industries. 

If you are interested in using CNC Swiss Screw Machine technology for one of your products contact us today at https://sheldonprecision.com/request-a-quote/

Article adapted from: https://www.thomasnet.com/articles/custom-manufacturing-fabricating/cnc-turning-swiss-machines/

CNC Machining Projected To Be $100 Billion Industry by 2025

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Recently, an increasing number of factories and production facilities have adopted CNC lathes as their tool of choice.  Experts expect the global CNC machine market to grow to $100.9 billion in value, an annual growth rate of 6.8%.

Lathe machines held a significant leading share of more than 27% in 2016.  Due to features such as reduced time requirements and multi functionality, industry analysts predict the milling machines segment to see a compound annual growth rate of an estimated 9.5%.  Through 2025, CNC Machining will likely continue to dominate this area of the market reaching and expected valuation of $25.17 billion. 

One of the most common prototype production methods, CNC machines operate automated tools using computer-programming inputs.  CNC machinery manufacturing is growing rapidly due to:

  • – Reducing operating costs
  • – Using manpower more efficiently
  • – Avoiding errors in manufacturing

CNC machining has many advantages in the manufacturing industry.  Computer-aided manufacturing (CAM) and computer-aided design (CAD) in product design and prototyping enhances manufacturers’ ability to create and deliver high-precision components on time.  This drives growth in learning about CNC machinery and adoption because CNC equipment reduces operating costs and improves the efficiency of mass production.  CNC machines allow accuracy when carving complex shapes such as diagonals and curves and the demand has become high with the rise of CAD, CAM and CNC software advancements. 

CNC machine operators save time between design and production which improves a facility’s capabilities and increases revenue.  CNC machinery provides more precise detailing than 3D printers and can work with a wider range of materials.  With improved production capacity, better quality and precision, CNC machines are the machine manufacturers should be using to help support a wide range of industries. 

Automotive, electronics, defense/intelligence, aerospace, healthcare and industrial manufacturers all benefit from the use of CNC lathes.  Though maintenance and services costs may be high and can somewhat affect adoption to the machine, reduced production costs and versatility of where you can use CNC machines can create significant growth opportunities.  

CNC lathes decrease time requirements in a fast paced production environment.  Production facilities are finding more use for CNC machines in their factories and are finding that quality precision and reduced labor costs will benefit production and

Contact Sheldon Precision today for your custom quote and be one of the early adaptors of this modern machine https://sheldonprecision.com/request-a-quote/

How CNC Machining Plays a Critical Role in US Military Weapons Systems

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Sheldon Precision is proud to support the mission of the US military by manufacturing precision machined parts using state-of-the-art CNC equipment and engineering. The precision offered by Swiss CNC machinery is critical to achieving the highest in quality standards and adhering to extremely tight tolerances required for military applications.

Sheldon Precision inventory of Swiss screw machining equipment combined with our experienced team of engineers and machines is the right combination for producing components for application in weapons systems, electronics, communications systems and other systems where complex and highly precise parts are required.  Our in-house quality system monitors machinery, processes and final parts and components to meet the highest quality standards. 

As an ISO 14001 and ISO 9001 registered company, Sheldon Precision is continuously improving the quality process. Every employee is involved in quality and lives and breathes it every day on the job. This fierce commitment to quality is how we deliver precisely what you need every time.

Additionally, Sheldon Precision is able to work with a variety of materials including titanium, aluminum and stainless steel.

At Sheldon Precision, we utilize a combination of CNC and cam driven Swiss Screw machines including:

  •  Escomatic
  •  Tornos
  •  Star CNC
  •  Milling & Secondary Equipment
  •  Advanced Inspection Systems
  •  

Our experienced staff works closely with our customers to understand their specific requirements and make suggestions on designs, materials and manufacturing for their specific needs.  If you are looking for more information or have a component design for quoting, contact us today at 203-758-4441 or click on the link for a quote https://sheldonprecision.com/request-a-quote/

CNC Machining & Swiss Screws in the Electronics Industry

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There is a large demand for speed and efficiency in much of todays’ industries. Manufacturing technology will need to continue to advance in order to meet such high demands. Both CNC Machines and Swiss screw machines can craft parts for the ever changing and advancing electronics market as devices get smaller and smaller.

Sheldon Precision meets the demands of the electronics industry with cost-efficient production and long or short run capabilities with the intricate parts in electronic screw machine products.

A Swiss screw maintains stability and allows for highly precise tolerances, even in tiny, long, narrow applications. Swiss screws are built for perfect precision, even in delicate parts with demanding tolerances. This is exactly what is needed to manufacture electronics.

A CNC Machine can produce parts at high speeds, with extremely tight tolerances, over and over. CNC controllers are the ideal solution for all applications used on the electronic components market.

Next time you happen to use a small electronic device, think about how it is probably comprised of parts manufactured by Swiss Screw and CNC machines. Contact Sheldon Precision today for your custom quote at https://sheldonprecision.com/request-a-quote/

More information is available on the following websites:

https://news.thomasnet.com/featured/swiss-screw-turning-vs-traditional-cnc-machining-/

CNC Machining vs. Traditional Machining

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The precision manufacturing industry relies heavily on computer-numerical control (CNC) machining, including operations that once used engineer-operated equipment like routers, shaping machines, vertical millers and center lathes.  Manufacturers of many types of industries choose CNC machining because it provides efficient, expedient and precise production capacity ideal for creating large quantities of items normally produced with a grinder, router, center lathe, or shaping machine.  

In manual lathing, there must be a skilled technician for every machine, while with CNC machining, one skilled person can operate several machines.  CNC machining can produce a broad range of metal components used across many industries use due to their accurate, consistent and complex cuts.  Some examples of these industries are:  aerospace, automotive, electronics, firearms, hospitality, manufacturing, metal work, military, production and transportation.  The first CNC machines were developed by US Air Force mechanics in the 1940s.  These early machines used punched-paper technology as a driver which has evolved into today’s digital software.  CNC machining grew popular due to its ability to produce detailed and precise results in large quantities by using computers.  

Computer Numerical Control is different from typical PCs because the software used to control the machine is specially customized and programmed with G-Code, which is specific to CNC, that allows precise control of speed, location, coordination and feed rate. One person can delegate the machine work that would be the equivalent of multiple operators on lathes, grinders, routers, mills and shapers which human operators and conventional machines don’t always do efficiently.  The manufacturing field finds CNC machining very useful because this industry needs large amounts of metal and plastic parts, often in complex shapes.  Different types of CNC machines have the advantage of multiple axes that can adjust to difficult angles and help manage hard to cut materials. 

Basic machines have a cutting implement along x and y axes that each work independently and simultaneously.  Advanced machines may have up to five axes that perform similarly and have the capacity to turn and flip the part.  CNC machines can automate the jobs that require several cuts.  A router or spindle turns the cutting implement, which resembles a drill bit, and cuts the material, while a true drill bit only cuts at the tip.  The programming in CNC machines incorporates all the exacting, high-speed movements needed to produce the object and enables detailed customization.  CNC machining is becoming increasingly popular to fabricate metal parts and plastic parts, since it allows the manufacturer to produce complex shapes that would be close to impossible to create manually.  Many industries look to CNC machining advantages for production solutions involving metal and plastic and any number of machining processes they may need.  

CNC and conventional machines both start with a raw chunk of metal or plastic and shape it into a part.  The main difference between the two machines is the automation of CNC versus the manual nature of conventional.  Speed, production rate and accuracy are some of the main advantages CNC machining has over conventional machining.  A skilled employee programs software to cut the parts in CNC machining while with conventional the employee sets up and operates the machine and gears.  Conventional costs less and is usually used for small-quantity projects.  CNC is used for high quantities and is not as cost-effective for smaller projects. A CNC machine uses three tools to cut parts, while conventional machines require five tools and more time to get the job done. Conventional and CNC technologies are available for most machining jobs. Some of these include drills – a bit spins to make contact with the material, lathes – the block of material moves against the drill bit, usually in lateral motion and milling machines – rotary-cutting tools remove material from a stock unit. Novel CNC machining technologies include less common types such as electrical/chemical where the material block is cut using a specific kind of machining style such as electron beams, electrochemical, electrical discharge, photochemical and ultrasonic. Less commonly found methods of CNC machining involve cutting media like lasers, oxy fuel, plasma and water jets.

The use of computer-aided design (CAD) software is used in CNC machining to produce a two or three-dimensional model of the final component. The prototype image of that component is fed into the software which operates through the computer to direct the machining tools to produce items identical to the model. Once the computer loaded a new image for CNC machining, it is able to pull up that model numerous times to produce more of the item. This is designed to achieve machining accuracy within .0001.

Conventional and unconventional methods of CNC machining are employed for a plethora of jobs that may involve a variety of materials such as:

Aluminium
Brass
Copper
Foam
Fiberglass
Plastic
Polypropylene
Steel
Titanium
Wood

These are 20 cutting chores frequently completed by CNC machining:

Bore
Contour
Cut
Drill
Engrave
Face
Grind
Groove
Knurl
Lathe
Mill
Punch
Shear
Shape
Stamp
Tap
Texture
Thread
Turn
Weld

Advantages of CNC Machining

Precision Components: The digital template and autonomous machining of CNC practically eliminates human error and achieve accuracy within 1/1000th.

Reliable Endurance: CNC machines work around the clock every day and only top for repair or maintenance.

High Production and Scalability: Once the design parameters and specification have been entered into a CNC machine, it consistently executes huge quantities and afford flexible scalability.

More Capability: When used in tandem with advanced design software, CNC machines create outputs that cannot be replicated by manual machines. Even the most gifted engineers can’t use conventional machines up to the level of CNC machines because of the advanced software that they use. These machines can produce any size, shape or texture needed.

Less Labor: CNC machining requires fewer personnel to execute the production tasks. One skilled operator can run several of the autonomous CNC machines while another programmer can get them loaded with the designs. A manual machines requires at least one skilled operator per machine and a supervisor. What you can save on manpower can be passed along to customers.

Uniform Product: When you use CNC machines over conventional machines, your CNC outputs match exactly. Even the most talented machine operations running traditional machines, their products will very slightly. Perfect parts are guaranteed every time with CNC machines.

Lower Costs: CNC machines have high speeds, are more efficient, precise and require fewer labor hours. Saving money or making more money is one of the popular benefits of CNC machining.

Fewer Headaches: Manual machines serve many great purposes but when your operator is out, or your staff isn’t performing up to their expectations you won’t produce as much as you would by using a CNC machine.

Better Safety: Even though CNC machines still require the use of operators, they are at a distance from the sharp tools. Operators of conventional-manual lathes, drills and punches come into direct contact with the implement.

Design Retention: Once the design has been loaded into the CNC machine software and it creates a perfect prototype, the program can easily retrieve the design and create the object over again.

Low Maintenance: The G-code based software will automatically update when needed and CNC machines usually do not require much service other than to change the cutting implements at the proper interval. None of the regular maintenance requires professional service.

Versatility: CNC machining creates virtually any component. Some of the models include special features and accessories that further expedite and simplify the production process.

There are many advantages to using CNC machines and at Sheldon Precision we only use the best machines to make sure your product is made with the highest quality possible. Contact us today for a quote at https://sheldonprecision.com/request-a-quote/

Article adapted from: https://www.fairlawntool.com/blog/advantages-cnc-machines/

Using Swiss-type Machines to Manufacture Medical Components

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The latest machining technology should be used in your warehouses and workshops to accurately create medical components.  Swiss-style lathes are a great combination of precision and repeatability due to their guide-bushing design, which provides support for the workpieces very close to the cut. Most businesses recognize that the US medical market offers more opportunities for those that create intricate components from tough materials. 

The United States has the largest and most sophisticated medical market in the world.  This is due to the aging population.  There are 35 million people 65 and older but by 2075 there will be about 69 million in the senior age group.  The rising cost of healthcare is another reason why the medical field is a new-business venture for many manufacturers.  Insurers and healthcare providers are creating pressure to reduce costs by increasing manufacturing productivity, which gives shops the opportunity to be capable to machine medical parts and devices in an efficient matter. 

Adopting the latest machining technologies becomes key for shops to accurately and repeatably create medical components.  The need for more sophisticated machining practices is driven by difficult materials, shrinking component sizes and the complex operations needed to create tight-tolerance features on these parts.  Swiss-style lathes offer a good combination of precision and repeatability for these applications due to their guide-bushing design, which provides support for the workpieces very close to the cut.

Many different areas and departments in the medical field can be served by shops using Swiss-type turning.  Some of these include interventional cardiology devices (stents, catheters and surgical tools); orthopedic devices (bone screws. implants and joint replacement); minimally invasive surgical equipment (laparoscopic devices); diagnostics (point of care testing instruments); wound care (staples, suture anchors and clips); and dental implants and equipment. 

Here are some tips for producing common medical component features and equipment on Swiss-type lathes:

Micro-machining is machining on a small scale that requires a proper mindset in terms of part handling, tool handling, inspection and secondary operations.  However, it starts with machine accuracy because even the best tooling won’t help if the machine lacks positioning accuracy.  Runout that might be acceptable for a standard-size part likely isn’t acceptable when machining features on tiny parts.  High precision collets are used for the machine’s main spindle, pickoff device and guide bushing.  High-frequency spindles are essential for drilling and milling tiny features into parts while achieving the desired surface finish, accuracy and tool life. 

When performing internal broaching, it is important to use the proper broaching tools and to prepare the workpiece for the operation.  Internal broaching requires creating a pilot hole with a 90 degree chamfer which prevents the broach’s points from chipping upon entering the cut and allows the broach to follow the centerline.  It may be necessary to remove material for the feature’s corners with a small end mill.  Deburring passes may also be required depending on the size of the chips. 

Wobble or rotary broaching uses a tool with a shape that’s similar to the final feature shape, except that it has a clearance ground into it.  The tool axis is typically inclines 1 degree from the workplace access and as the broach rotates, it presses against the workpiece. The 1 degree incline causes the leading edge of the tool to “wobble” with respect to the workpiece.  If the tool is inclined by 1 degree, the sides of the tool must have a clearance angle of at least 1 degree since the tool advances at the same rate it cuts. Wobble broaches do not cut as accurately as a punch broach, so their use should be determined by the application it will be used for. 

Thread whirling is often used to cut special form threads in difficult to machine materials and is not as limiting as other threading operations.  Thread whirling is typically used for bone screws that have a significant length to diameter ratio; deep, high-helix buttress threat forms and extreme differences between major and minor diameters.  ID thread whirling is effective for producing clean, burr-free thread contours with no residual chips and it enables threading down to the bottom of a hole to sizes as small as 0.0551 inch.  An alternative to thread whirling includes a die head (not to be used on materials such as titanium), thread milling (requires pre-turning, special cutters and special supports in certain cases), single point turning (used for short screws since long screws need support), thread rolling (requires accurate pre-turning and doesn’t work on buttress-style threads in hard materials) and grinding, which can’t be performed on a Swiss-type lathe.

Cannulated bone screws, (screws that are hollow) have a space that allows bone marrow to grow.  This also facilitates the insertion of guide pins for bone screws used in fracture fixation.  The demand for cannulated bone screws is increasing even though it can be expensive.  Gundrilling allows shops to machine these screws effectively from solid bar stock.  It offers high drilling quality, process reliability, effective chip removal, minimal runout and significant length to diameter ratios. 

If you are interested in manufacturing high quality components for the Medical Industry contact us today https://sheldonprecision.com/request-a-quote/

Article adapted from

https://www.mmsonline.com/articles/consider-swiss-types-for-medical-opportunities