Definitive Guide to

CNC Machining
Explore Process, Part Design, Materials,
and More for Subtractive Manufacturing
Contents
04 Optimizing Part Design for Machining 29 Complex Features

07 
Designing for CNC Turning 32 High-volume Machining

10 Material Selection 35 Why Protolabs for CNC Machining

14 
Understanding Tolerances

17 Mistakes to Avoid

20 
Threading Considerations

25 Post-processing Options

Upload a Part!
Get an online quote with design
for machinability analysis today.

Definitive Guide to CNC Machining 2

Introduction
It was a simple and predictable idea that has forever changed how parts are manufactured. When modern
computer-based control of machines was developed in 1949 by James Parsons at the Massachusetts
Institute of Technology, the aim was to make aircraft parts that had consistency and durability. It was kind
of clunky (are any version 1.0 tools perfect?) and used the technology of the day—punched paper tape—
to convey model information to the machine, but it did what it set out to do.

Today, we’ve moved well past spools of punched paper tape. In modern digital manufacturing, CNC
machining is part of a digital thread that takes customer-uploaded 3D CAD models and runs them through
a design for manufacturability (DFM) evaluation. Once any issues are fixed in the CAD model, the digital file
is translated into G-code, which tells the machine how to cut away metal or plastic material to define the
desired shape of the model as an actual 3D object.

On some of today’s mills, the machining process can take place on five different axes without removing
and restaging the part in a fixture, making for faster, more accurate output. And hey—don’t forget about
CNC turning, which uses your 3D CAD models to create cylindrical parts. Turning on a high-speed lathe
is basically the same idea as cutting away slivers of wood from a maple log as it spins on its long axis,
ultimately making a baseball bat. It takes time to do it right, but we mill and turn parts 24/7.

This guide offers a comprehensive look at CNC machining, from milling to turning and prototype to
production. It offers design dos and don’ts and lists materials you’ll want know more about to help you
create the best parts.

Definitive Guide to CNC Machining 3

Optimizing
Part Design
for Machining
Manufacturing prototypes and production parts
quickly and cost-efficiently is often a balancing act
of quick-turn CNC machining capabilities and an
optimized part designed for those capabilities.
To fully optimize
your design for
CNC Machining is a Subtractive Process
You start with a particular metal or plastic—in block or rod form—and
remove material until you’ve achieved the desired geometries, based
2 Threading
Right
Drilling and thread-making go hand in hand. Many shops use taps to
on your CAD model. But let’s think about the complexities of that.
machining, you In the wink of an eye, just the slightest miscalculation in your milling
cut internal threads. Taps look like a screw with teeth and are threaded
into a previously drilled hole. Protolabs takes a more modern approach
angle or in the original design could send your part into the recycling
should consider: bin (Yes, we recycle!). However, it’s not just about how you cut
to thread-making, using a thread mill to interpolate the thread profile.
This creates an accurate thread. Best of all, you can use a single-size
something. You also have to think about the properties of the material
mill to cut any thread size that shares that pitch (the number of threads
u Hole depths and diameters to ensure that it can endure the incredibly fast rotations of the tool that
per inch)—saving you time in setup and production. Because of this,
mills it or trims it off on a lathe. In the end, it’s kind of like sculpting, but
UNC and UNF threads from #2 up to 0.50 in., and metric threads from
u Size and types of thread
with no human hands involved in removal of material. STANDARD
M2 to M12 are possible, all within a single toolset. We’ll take a closer
u Text on parts look at threads on page 20.
HOLES
Manufacturing prototypes and production parts fast and cost-

u Wall heights and feature widths efficiently is a balancing act of automated CNC machining
capabilities and an optimized part designed for those capabilities.
u Live-tool lathes So, there are a handful of important considerations when designing
parts for Protolabs’ milling and turning processes that can accelerate
u Multi-axis milling production time while reducing costs.

1 The
'Hole' Truth
Anyone who has spent more than five minutes in a shop knows what a
Maximum
Thread Depth

drill bit looks like and what it does. For the most part, however, holes
at Protolabs are machined with an endmill, rather than drilled. This
machining method provides great flexibility in terms of the hole sizes
available with a given tool and offers better surface finish than what
you get with a drill. It also allows us to use the same tool for machining
slots and pockets, reducing cycle time and part cost. The only
Minimum / Maximum
downside is that holes much more than six diameters deep become a Modeled Diameter
challenge due to an endmill’s limited length and may require machining
from both sides of the part, which adds production time.

Definitive Guide to CNC Machining 5

3 Be Careful
Texting 5 Live Tool
Lathes 6 3-Axis and
5-Axis Machining
Sometimes, milling a part number, description, or logo is Aside from extensive milling capabilities, we offer live-tool We use two distinct flavors of milling. With 3-axis machining,
necessary for your part design. Machining text, though, also CNC turning, too. The toolsets used on these machines are the workpiece is gripped from the bottom of the raw material
adds cost. And the smaller the text, the higher the cost. That’s similar to the ones on our machining centers, except we do blank while the part features are cut from up to 6 orthogonal
because the very small endmills that cut the text operate at not turn plastic parts at this time. That means off-center holes, sides. With parts larger than 10 in. by 7 in. (254mm by 178mm),
a relatively slower speed, increasing run time on your part slots, flats, and other features can be machined parallel or only the top and bottom can be machined: no side setups! With
and therefore your final cost. You do have options, however. perpendicular (axial or radial) to the long axis of the turned 5-axis indexed milling, however, machining from any number of
Our toolsets are capable of machining pretty much any text workpiece (its Z-axis) and will typically follow the same design non-orthogonal sides is possible.
required, provided the spacing between individual characters rules as those applied to the orthogonal parts made using our
In either case, the toolsets used are identical. What’s different is
and the stroke used to cut them measures at least 0.020 in. machining centers. The difference here is in the shape of the
the raw material. As with our lathes, rod stock is used for 5-axis
(0.5mm). Also, text should be recessed rather than raised. For raw material rather than the toolset itself. Turned parts such as
milled parts, which presents some interesting mathematical
best effect, use 20-point or larger fonts such as Arial, Helvetica, shafts and pistons start out as cylindrical stock, while milled
discussions about the size, geometry, and positioning of the
Verdana, or a similar sans-serif font. parts—manifolds, instrument cases, and valve covers, for
part within that raw material volume. For some examples of this,
example—typically don’t. They use square or rectangular blocks
you can stare at the accompanying diagrams for a while, or just
instead. Lots more about turning coming right up!

4 Tall Walls
and Tiny Features
upload your part model online at protolabs.com.

Our toolsets contain carbide cutting tools. This super rigid

material offers maximum tool life and productivity with 2.0 in.
(50.8mm)
minimal deflection. But even the strongest tools deflect, as do 3.9 in.
(99.06mm)
the metals and especially plastics being machined. Because
of this, wall heights and feature sizes are very dependent on
both the individual part geometry and the toolset being used.
For instance, the minimum feature thickness we recommend 2.0 in.
(50.8mm)
is 0.020 in. (0.5mm) and the maximum feature depth is 2 in.
(51mm), but that doesn’t necessarily mean you can design a
ribbed heatsink using those dimensions.

Live Tool Lathes: The part above was made with a CNC lathe using live tooling. 3-Axis and 5-Axis Machining: This illustration shows how a part using 5-axis
machining fits within a block of material using the maximum part extents.

Definitive Guide to CNC Machining 6

Desigining for
CNC Turning
It was once a no-brainer. Round parts were turned on
lathes; non-round parts were machined on mills. With
the advent of CNC machining centers, which interpolate
round part features with ease, the line between the two
machining processes has become blurred.

The situation grew even more confusing when CNC

lathes attained live-tool capability. Operations that were
once the exclusive domain of the milling department
were now coming off the lathe complete. As a result,
deciding which machine is the best fit for producing any
given part has become more complicated.

Our turning operations offer you a variety of materials to

work with, such as aluminum, brass, low carbon steel,
stainless steel, steel alloy (4140), and titanium. Protolabs
does not currently turn plastics.
 Everyday Examples
If you’re still unsure about what parts are lathe-worthy,
consider a few household objects. A pint glass, for example,
with its smooth, regular shape and length several times
greater than the outside diameter is a straightforward exercise
on a lathe. Not so on a machining center. A coffee cup, on the
other hand, with its jutting handle and finger-ready hole, is
impossible to turn.

Those 3-lb. dumbbells collecting dust in the closet could

be turned fairly easily on a lathe. The wide, relatively deep
recessed area where your hand grips the bar can be turned
with a simple grooving routine, a feature that would be
murderous to cut on a milling machine.

A small teacup saucer could go either way. Interpolating the

Candidates for Lathe concentric ridges and curved surfaces can be done on a mill
Some parts are obvious lathe candidates. Consider the piston for a spool valve, or a hydraulic fitting.
or a lathe, requiring nothing more than accurate G-code and a
The cylindrical symmetry of these components, coupled with complex external geometry and challenging
suitable cutter. That said, it would almost certainly be faster to
internal features, makes them perfect for the turning department.
turn the saucer, and far more efficient in terms of material use.
Conversely, the rectangular valve body that mates with those turned parts, with its large, milled surfaces,
How about a hose barb for the sprinkler? The v-shaped
detailed pockets, and intersecting bores will never be spun on a lathe, no matter how live-tool capable
grooves would require a special cutter on a machining center,
that machine may be.
whereas a lathe can use a standard turning tool. The same
These are some of the reasons why our CNC machining service has turned to, well, turning. By adding live- holds true with a replacement wheel for a barbecue grill,
tool (end mill) equipped CNC turning centers to our already extensive 3-axis milling service, we’re able to although milling those little mag wheel-like cutouts on the
improve surface finish on cylindrical features and typically do it at a lower price for customers. A lathe also face would be challenging or outright impossible on most
makes more efficient the manufacture of those parts that may skate on the edge of our milling capabilities. turning machines.
And if the goal is eventual low-volume production, turned parts are good candidates.
Soup cans and salt shakers, water bottles and flower pots—
Turning parts can offer several advantages over milling. As implied previously, long length to diameter these shapes are what lathes are all about. Milk cartons and
ratios on pistons and shafts are better suited for the lathe. picture frames? Not so much.

Definitive Guide to CNC Machining 8

Lathe Capabilities
When it comes to size, we’ll tackle parts up to 3.95 in. (100.33mm) in diameter by 9 in. (228mm) long, and as
small as 0.16 in. (4.07mm) diameter by 0.050 in. (1.27mm) long. Sharp conical points are okay, as long as the
angle is greater than 30 degrees. No promises on ballpoint pen prototypes, or models of soda straws.

As mentioned earlier, our new lathes have milling capability. Drilling a side hole or milling a flat is well within
their means if that feature is parallel or perpendicular to the long axis of the part. Any milled grooves should
be wider than 0.047 in. (1.2mm), but because our lathes are equipped with a Y-axis, we can machine slots or
holes off-center (within reason).

Need your company’s name engraved on the parts? With a lathe, raised text is best, but we can machine
most any lettering if the line width and character spacing measures at least 0.020 in. (0.5mm) across. Small
holes don’t scare us off, nor do threads. In fact, we’ll drill radial holes down to 0.080 in. (2mm) and axial
holes half that size. Likewise, we support a range of internal and external UNC, UNF, and metric threads.
Getting a Turning Quote
Like all machined parts, the process begins with entering your CAD
You’re likely to notice that turned surfaces are smoother and rounder than their milled counterparts.
model into our automated quoting system. Our software will determine
Milled features may have visible tool marks, but we can bead blast these surfaces to give them a matte
the best machining method (milling or turning) for each material. You
finish and knock down any small burrs that remain after the machining process. We’ll talk about finishing
can sometimes override this decision when you configure the quote.
options later in this guide.
Pricing and capabilities vary based on which process you choose.
We’ve found over the years that making round parts out of square or rectangular stock can leave a few When you configure the quote, select the machining process that
things to be desired. Milling away the square corners to get to the round part underneath takes longer than best meets your needs after weighing these factors. If a part does
turning it from bar stock. It also creates more material waste. Turning those parts in a machine designed not qualify to be turned in a particular material, this option will not be
for such work is certain to be a win-win for everyone. To learn more about turning at Protolabs, check our available in the quote for that material. Give it a try!
process and guidelines page or upload your part now to see if it qualifies.

Definitive Guide to CNC Machining 9

Material
Selection
The raw metal or plastic you choose to use for
your parts is just as important as how the parts
are machined. Selecting the wrong material could
unnecessarily balloon part costs. For instance,
superalloy and darling of the aerospace world,
titanium, is hard to machine and parts made of it
will almost certainly cost more than ones made of
aluminum or stainless steel. Often that is also the case
with plastics PEI and PEEK. The point? If it’s not truly
needed, opt for a more inexpensive material.
Part Design Priorities Some technical considerations that will help you choose a suitable material for your part’s application
include specific measurements such as tensile strength, heat deflection, and overall hardness. Find these
specs in our materials for machining data sheets.
Environmental
This covers heat and cold resistance, flame retardance, Ready to compare? Here are some of the more common materials used for machined parts, along with their
and UV- and chemical-tolerance. Do you need food-grade key properties. The list isn’t exhaustive—we carry more than 40 different metals and plastics for milling
or medical-grade materials for your parts to endure an and 10 metals for turning—but it basically hits the highlights.
autoclave’s extreme heat or harsh chemical sterilization?

Electrical
A part may need to conduct, insulate, or dissipate static. Comparing Machining Materials
In any of those cases, choosing the right metal or plastic
resin will be critical. Electrical Impact Chemical Wear/Abrasion Temperature Moisture
Metals
Conductivity Resistance Resistance Resistance Resistance Resistance
Mechanical Aluminum X X X X
A part may need to fall anywhere on a continuum from rigid to
Cobalt Chrome X X X X X
flexible. It may require tensile strength, compressive strength,
Inconel X X X X X
or be impact resistant. Some parts may have to resist wear or
Stainless Steel some use 4140 X X X X
provide lubricity to function, as does a bearing.
Steel X X some
Cosmetic Titanium X X X X X
Typically, cosmetics are a secondary consideration, but
they can be essential. Some materials offer transparency or Impact Chemical Wear/Abrasion Moisture
Plastics Temperature Transparency
translucency, and plastics can come in a variety of colors, while Resistance Resistance Resistance Resistance

metals can be colored in finishing. Plus, don’t forget textural ABS X X X some
finishes, which vary from non-slip to high polish. Acetal X X X

Size Delrin X X X X

While machining can produce parts in a range of sizes, Nylon X

part size can be limited by the maximum available size PC X X X X X

of a particular stock material. PEEK X X X X X
PEI X X X X X amber-shaded
Cost
Cost can be an important factor that will typically fall
somewhere between the must-haves and the nice-to-haves.

Definitive Guide to CNC Machining 11

Metals
Aluminum Stainless Steel Steel Titanium
A broad assortment of aluminum alloys exists, By adding a minimum of 10.5 percent Often, this is the go-to metal for many Titanium is extremely strong and boasts a high
but the most common are 6061-T6 (considered chromium, reducing the carbon content to a applications, but of course, steel has it’s good strength-to-weight ratio. It also has excellent
a general-purpose alloy) or 7075-T6 (a favorite maximum of 1.2 percent, and tossing in some and bad attributes: corrosion resistance, high operating temperatures
of the aerospace industry). Both are easy alloying elements like nickel and molybdenum, (up to 1,000°F) and is nontoxic. Another key
u Steels generally cost less than
to machine, corrosion resistant, and exhibit metallurgists convert ordinary rust-prone steel benefit of titanium is its low thermal expansion
stainless steels and superalloys.
high strength-to-weight ratios. Keep in mind into stainless steel, the corrosion-proof switch and high melting point (~ 3,000°F). Often,
that Protolabs offers traceable UT-tested hitter of the manufacturing world. Stainless u In the presence of air and humidity, all you’ll find titanium parts used in the aerospace,
aluminum for milled parts. It is identical to steels 303, 304, and 316L have a crystalline steels corrode. medical, military and marine industries.
standard aluminum 6061-T6 but is ultrasonic structure that make them non-magnetic, non- u Most steels are quite machinable,
tested and guaranteed to conform to ASTM hardenable, ductile, and quite tough. 17-4 PH is with the exception of some tool steels.
B 594 and AMS- STD-2154 specifications. favored for its excellent mechanical properties.
Aluminum is suitable for airplane parts, u The lower the carbon content, the less hard

computer components, cookware, architectural steels can be made (indicated by the alloy’s

components, and more. Here’s a quick first two digits, as in 1018, 4340, or 8620,

comparison: three common selections). That said, steel,

and its cousin iron, are among the most used
Aluminum 6061 vs. 7075 metals, with aluminum a close second.
u 6061 offers excellent machinability,
low cost, and versatility

u 7075 offers high strength, hardness,

low weight, and heat tolerance

Definitive Guide to CNC Machining 12

Plastics
ABS PEI (Ultem) Polyetheretherketone (PEEK)
More affordable than comparable thermoplastics Another truly tough plastic choice, PEI offers high The Superman of polymers, PEEK can replace
with superb mechanical properties like toughness, heat and impact resistance. Glass fiber is often added metal in certain applications but prepare yourself
hardness, and rigidity. ABS has high impact to enhance an already rugged product. You can even for sticker shock. It typically costs five times more
resistance and surface hardness under high and add lubricity (slipperiness), making it a great choice than other high-performance thermoplastics.
low temperatures, terrific dimensional stability, for ball bearings and pivot joints. We offer: Ultem
Typical parts:
and a higher heat deflection temperature than its 1000 and Ultem 2300 (30% Glass-Filled).
u Bearings
thermoplastic counterparts.
Typical parts: u Thrust washers and seals
Typical parts: u Medical and dental devices u Piston parts
u Electronic housings u Automotive parts u Semiconductor fabrication
u Plumbing u Electrical connectors u Pumps and compressor plate valves
u LEGO toys u Aerospace parts

Nylon Polycarbonate (PC) POM (Delrin)

A go-to material choice for mechanical components An engineering plastic with excellent dimensional This acetal homopolymer has excellent durability
that will experience wear and friction. As with PEEK stability and good strength and stiffness. It's a go-to and low moisture absorption. It’s a good material
and Delrin, sometimes it can be used as a metal material for parts that need clarity and impact strength. option for mechanical components and industrial
replacement. We offer: Nylon 6 Light Blue, Nylon 6/6, We offer four grades of machined polycarbonate: Black, products and can sometimes replace metal.
Nylon 6/6 30% Glass-Filled Natural, Nylon 6 Black. Clear, Translucent, 20% Glass-Filled. We offer four grades of delrin/acetal homopolymer.

Typical parts: Typical parts: Typical parts:

u Gears and bearings u Gears and rollers u Gears and bearings
u Sprockets u Internal mechanical parts u Sporting goods
u Sheaves u Pumps u Electrical insulator parts
u Light bezels u Connectors and fittings
Upload a Part!
Get an online quote with design
for machinability analysis today.

Definitive Guide to CNC Machining 13

Understanding
Tolerances
Tolerances represent the amount of variance you
can expect when your parts are turned or machined.
Essentially, they set the typical limits—plus or
minus—on the accuracy of the features.
Working with Standardized Tolerances for CNC Machining
The standard prototype and production machining tolerance at
One Step Beyond: Geometric Dimensioning and
Tolerancing (GD&T)
Bilateral Tolerance Protolabs is +/- 0.005 in. (0.13mm). This means any part feature’s
location, width, length, thickness, or diameter will not deviate by
Here’s another possibility. We can accept GD&T tolerancing. This
provides a deeper level of quality control that includes relationships
Be aware that these are bilateral tolerances. more than this amount from nominal. For example, the 1 in. (25.4mm)- between various part features as well as form and fit qualifiers. Here
If expressed in unilateral terms, the stan- wide bracket you're planning to order will measure between 0.995 are a few of the more commonly used ones:
and 1.005 in. (25.273 and 25.527mm) across, while the 0.25 in.
dard tolerance would read +0.000/-0.010 u True position: With GD&T, a hole’s location is called out by its
(6.35mm) hole on one leg of that bracket will come in at 0.245 to
in. (or +0.010/-0.000 in.) while a limit-based true position from a set of reference points, accompanied by
0.255 in. (6.223 to 6.477mm) diameter.
tolerance in our bracket example would be the qualifiers MMC (maximum material condition) or LMC (least
1.005 / 0.995 in. That’s pretty close, but if you need greater accuracy, there's our material condition).
standard precision or production machining tolerance of +/-0.002
All are acceptable, as are metric values, in. (0.051mm). We're also able to hold +/- 0.0005 in. (0.0127mm) u Flatness: Milled surfaces are generally quite flat, but due to internal
if you spell them out on the design. And on reamed holes, and +/- 0.002 (0.051mm) on feature locations, material stress or clamping forces during the machining process,
to avoid confusion, please stick with the provided those features are machined on the same side of the part. some warpage can occur once the part has been removed from the

"three-place" dimensions and tolerances Depending on the part geometry and material, however, we can often machine. This especially happens on thin-walled and plastic parts.
achieve even greater accuracy, provided you make us aware of your A GD&T flatness tolerance controls this by defining two parallel
shown, avoiding the extra zero in 1.0000
requirements. For these and other exceptions, please be sure to note planes within which a milled surface must lie.
or 0.2500 in. unless there’s an overriding
reason to do so. them on your part design when you upload the file(s) for quoting. u Cylindricity: This focuses on the roundness of a milled hole or
Surface Roughness Considerations for Machining a turned surface. However, using a +/- 0.005 in. (+/- 0.127mm)
Tolerances tolerance, a 0.250 in. (6.35mm) hole could potentially be oblong,
There’s more to part tolerancing than length, width, hole size, etc. measuring 0.245 in. (6.223mm) one way and 0.255 in. (6.477mm)
There’s also surface roughness, which in the standard offering is the other. Using cylindricity—defined as two concentric cylinders
equal to 63 µ in. for flat and perpendicular surfaces, and for curved inside of which the machined hole must lie—we can eliminate this
surfaces, 125 µin. or better. unlikely situation.

This is an adequate finish for most uses, but for cosmetic surfaces u Concentricity: The rings on a bullseye are concentric, just as the
on metal parts, we’re generally able to improve appearance through wheels on your car are concentric to the axle. If a drilled or reamed
light bead blasting. If you need something smoother, note it on your hole must run perfectly true to a coaxial counterbore or circular
design and we'll do our best to accommodate you. boss, your best bet is a concentricity callout.

Definitive Guide to CNC Machining 15

u Perpendicularity: As its name implies, perpendicularity determines the maximum deviation of
a horizontal machined surface to a nearby vertical surface. It can also be used to control the
squareness of a turned shoulder to an adjacent diameter or the center axis of the part.
There are additional GD&T dimensions you can include, including parallelism, straightness,
profile, and angularity, all of which are spelled out in ASME Y14.5. As with any other non-
standard tolerances, however, they must be called out in the design at the time of upload.
Tolerancing with GD&T also means that projects will bypass our automated Protolabs quoting
process and be rerouted to our myRapid quoting experience—our CNC machining high-
precision/high-quantity option.

Why High-Precision, High-Quantity Machining?

So, what is the difference between our machining options? For starters, as noted above, a quote
for high-precision, high-quantity machining is not automated as it is with our standard machining
option, so the quote might take a day for human review. With high-precision machining, the finished
part lead-time is also a little longer, with five to 10 days as standard. We require a 3D CAD model,
along with a 2D drawing for GD&T tolerances. It could also mean that we go beyond our standard
cutting tool set and use machining processes such as EDM hole popping, grinding, and boring to
meet your part quality requirements.

Quality Control and Documentation Options

Upon request, we’ll measure parts on one of our coordinate measuring machines (CMMs)
and other metrology equipment. We will also work with you on the Production Part Approval
Process (PPAP), provide a Certificate of Conformance (CoC) to your specifications, and
provide First Article Inspections (FAIs), material certifications, and heat lot numbers.

Definitive Guide to CNC Machining 16

Mistakes
to Avoid
For all of the technology that makes one-day part
turnaround possible, it is usually the human element
that emerges as the culprit in recurring issues we see
in parts designed for CNC machining.
1 Avoid Features That Require
Unnecessary Machining
One frequent mistake is designing a part with areas that don’t need machine cutting. Such
unnecessary machining adds to your part’s run time—run time that’s a key driver of your final
production cost. Consider this example, where the design specifies a critical circular geometry
needed for the part’s application (see illustration). It calls for machining the square holes/
features in the middle and then cutting away the surrounding material to reveal the finished part.
That approach, however, adds significant run time to machine away the remaining material. In
a simpler design (see illustration), the machine simply cuts the part from the block, eliminating
the need for additional, wasteful machining of excess material altogether. The design change in
this example cuts machine time nearly in half. Keep your design simple to avoid extra run time,
pointless machining—and added cost.
Avoid Unnecessarily Complex Designs: The design on the right will require
significantly less milling time—saving you money.

2 Avoid Tall,
Thin Walls
Wall features in part designs are generally tricky. As we mentioned earlier, cutting tools are
incredibly rugged, but they (and the material) can still deflect during cutting due to the mill’s
rotational forces, resulting in issues such as an undesirable rippled surface and difficulty meeting
part tolerances. Worse yet, walls can chip, bend, or break. Here are some other wall design specs
to keep in mind:

u The taller your wall—our maximum is 2 in. (51mm)—the thicker it may need to be to increase
the rigidity of the material.
u Thin walls of 0.020 in. (0.508mm) or less are subject to breaking during machining and may flex
or warp afterwards.
u Try not to design walls too thick as the cutting tool usually is spinning at 10,000 to 15,000 rpm.
u A good rule of thumb for walls is a width-to-height ratio of 3:1.
u Adding some draft to a wall—an angle of 1, 2, or 3 degrees so that it tapers rather than standing
Avoid Unnecessarily Complex Designs: The design on the right will require
vertical—could make machining it easier and leave less leftover material. significantly less milling time—saving you money.

Definitive Guide to CNC Machining 18

3 Avoid Small Pocket Features
You May Not Need 5 Reconsider Machining Parts
That Will Eventually Be Molded
Some parts incorporate square corners or small internal corner pockets to reduce overall weight or We often see designs for injection-molded parts uploaded to our machining service for
to accept other pieces of an assembly. Internal, 90-degree corners and small pockets, however, are prototyping before buying a mold. But each process has different design requirements, and the
too small for our larger cutting tools. Creating those means picking away at the corner material with results can differ. A thick machined feature may suffer sink, warp, porosity, or other problems
smaller and smaller tools. That could result in using six to eight different cutting tools. Those tool when molded. A well-designed molded part with ribs, pockets, and other features will require
changes drive up run time—and you guessed it—your project’s cost. To avoid this, first determine prolonged run time to machine. The point here is part designs are typically optimized for their
how critical the pockets really are. If they are there only to reduce weight, revisit your design to manufacturing process. Talk to our team first for advice on how to modify your design for a
avoid paying to machine material that doesn’t need to be cut. The larger the corner radius you molded part for machining, or simply prototype your parts in their final production process—
design, the bigger the cutting tool we can use, and the less run time it will take. injection molding. At Protolabs, the initial cost investment for prototype tooling is very low.

4 Avoid Creating Holes

That Can't Be Threaded
As we mentioned in the chapter on optimizing your designs, we can easily add threaded holes to
your machined parts. But designing threads so that our quoting software will see them—and so
they will get machined into your part—can be challenging. Our quick turn process has a static set
of threads available. When our software analyzes your part, it looks for a hole diameter that will
correspond to one of those threads. If you want a UNC or UNF #5-40 thread, for example, the
software looks for a hole with a diameter that’s within the range for that thread. If the diameter
isn’t within that range, you won’t be able to assign that thread to your part. This often is when
customers call and when we refer them to our quick-reference Threaded Hole Guidelines
webpage. There, you’ll find the types of threads we have available. Click on a particular thread
to go to a chart with the range of hole diameters to choose for it. Choosing a diameter that’s 75
percent of the hole drill size—each chart includes that dimension for every thread—will always
work. As you’re designing your part, go ahead and use your CAD software’s thread wizard—most
customers do. But confirm with our charts that the wizard is outputting a hole diameter that
works with our software. Learn more considerations for thread design here.

Definitive Guide to CNC Machining 19

Threading
Considerations
Incorporating threads in your parts can sometimes
be the ultimate undoing of your assemblies. There
are a lot of design rules, and you need precision to
manufacture threads and ensure that they work right.
External vs. Thread Pitch
When we talk about threads on bolts and screws, it’s not a one-size-
With turned parts, there are three types of holes you can use to
accommodate internal threads:

Internal Threading fits-all kind of scenario. In addition to metric threads, there are three
primary kinds of imperial measure threads that are part of the Unified
1. On-axis: holes that go straight through the center of a turned part,
starting at one end
This is pretty basic, but important. An easy Thread Series.
2. Axial: holes that start at one end of a part, but don’t go perfectly
way to remember this difference is that u UNC (coarse pitch): 20 threads per inch (tpi) through the center
you'll find external threading on screws and u UNF (fine pitch): 28 tpi
bolts—it’s external to the hardware. Internal u UNEF (extra fine pitch): 32 tpi 3. Radial: holes that pierce through the exterior arc of a turned part

threads reside inside the main part. They Note that adding UNEF thread pitch requires our precision machining
accept, and lock in, screw and bolt threads. service, accessible via our quoting system. For example, if you want
to incorporate a #4-40 screw, you know that a #4 screw—which
has a thread diameter of 0.11 in. (2.794mm) has 40 threads per inch,
meaning extra fine pitch.

The good news is that when you use our system to assign a particular
type of screw to a hole, the desired thread pitch comes along for the
ride. Less worries are always good, right?

Where Can I Place a Thread?

Really, a thread can be placed almost anywhere that makes sense for
the turned or milled part and your assembly’s needs. As long as the
area in which the thread will go is accessible to our equipment, you’re Three Types of Holes For Threaded Parts: On-axis, Axial, and Radial.
good to go. If there are obstructions to prevent it, our design analysis
software will let you know.

Even though it seems like there aren’t a lot of placement restrictions

when it comes to threading, the depth of an internal thread is
important to consider. If the thread depth exceeds the maximum
depth for the tooling, we may have to drill through from both sides of
the hole to complete the process. When that happens, it’s important
to know that your threads will not be continuous from one end to the
other, but there are options we’ll go over in the next section.

Definitive Guide to CNC Machining 21

Internal Threads
Internal threads are machined using a single-lip threading tool—not a traditional threading tap.
On parts with internal-hole features in need of threading, the actual threads need to be removed
from your CAD model, leaving only the pilot diameter. Protolabs' design analysis software recognizes
a hole for threading if:

u it falls within the diameter range for the desired thread and,

u is on one of the three cardinal axes for milling or,

u is perpendicular to the axis of revolution for turning.

We supports right-hand threaded holes on machined parts for UNC and UNF threads ranging from a
#2 and up to 1/2 in. (12.7mm) metric threads are also available, ranging from M2 to M12. Location and
method of manufacturing may limit some threads from becoming eligible. We also offer NPT threads
for aluminum, copper, and brass parts.

In machining internal threaded holes, a hole may be longer than what our threading tools are able to
From Left to Right: Images 1, 2, and 3 depict three methods of approaching maximum thread depths.
reach. In this case, you have a few options depending on your needs:

u With a long through hole that exceeds the maximum reach, select the hole from the side that you
anticipate the screw to be started from (see image 1 in three-panel illustration). If your screw is
required to pass the entire way through the part, you would also have to pass a tap through the hole
(in a secondary process) to complete it.

u You can also select both sides of the feature to be threaded (see image 2 in illustration) but notice
the maximum thread depths as they overlap with each other in the hole. This raises concern with
threading the features from both sides, because you risk cross-threading and a screw may not pass
Know Your Diameters
One important consideration with internal threads has to do with the
all the way through the part cleanly. As long as the threads don't intersect (see image 3), selecting
various diameters involved with creating threads. There are three:
threads from both sides is typically fine.
1. The major (wide) thread
If your designs instruct your manufacturer to mill out a pilot hole that’s the same diameter as the major
(wider) thread, the hardware you use will never fit properly in the hole. Instead, the screw will likely 2. Minor (narrow) thread
spin around endlessly in the hole. Save yourself some trouble: Make sure that any threaded feature’s
3. Diameter of the pilot hole for your threaded feature
pilot hole reflects the minor diameter of your thread. Most CAD programs have built-in wizards to help
with this process.

Definitive Guide to CNC Machining 22

External Threads
Designing Smaller
The great thing about external threads on turned parts is that the thread can extend the length of the
part, if your parts qualify for turning. We use a custom threading tool with a selection of thread sizes, External Threads
depths, and placements within the part geometry. However, our advanced turning process offers Protolabs’ extensive machining capabilities include 5-axis mills,
external threads on the centerline of the part, and live tooling that allows threading of internal holes, which allow for simultaneous movement on up to five machine axes
if they follow similar guidelines as milling. We offer external threading for on-axis, axial, and radial while the cutting tool is engaged in the workpiece. Complex “swept
holes. Milling external threads is done in two stages. The first set of threads go halfway around your surface” parts like boat propellers, orthopedic implants, and turbine
turned part, followed by thread milling on the other side. The two sides meet along the centerline blades can now be manufactured with fewer setups.
of your part. This process works well for 1/2-inch threads, but we do advise chasing the threads to
remove excess material or smooth out mismatches in threading.

Just like internal threads, external thread design requires that the thread be removed from the CAD
model for our software to recognize it. Additionally, please model your external threads for milling;
don't model them for turning. After you receive your quote for turning, you will have the ability to
select the appropriate thread size.

Alternatives to Threading
For most metal parts, threading is a great way to achieve a strong bond
between elements of your assembly. But sometimes that’s not enough,
especially with parts made from waeaker materials, such as plastics and
aluminum. That’s where inserts come in handy. Consider incorporating
special coil inserts in plastic parts to ensure longer part life. These
rugged little disks allow you to get strong threading, even on weaker
material. Essentially, you’ll design a hole in the desired location, and you
can add the inserts to your parts later. We will mill out the hole to your
specification and prep it to receive your insert. Protolabs is optimized for
HeliCoil brand inserts and we recognize standard sizes and lengths.

Definitive Guide to CNC Machining 23

How to Incorporate Threading into Your Quotes
In our quoting system—adding threaded features is pretty simple. Our software recognizes
holes that could potentially include threading and then asks you what kind of threaded
hardware you want to use there.

Selecting both internal and external threads on part features is easy in our system. In your
quote’s Thread Assignment tab, you will notice a fully interactive model that allows you to
select which threaded features are available. Each eligible feature is highlighted, and you
can manually select threads.

If a thread you want isn't available, you may need to double-check the diameter of
your features to make sure they are within the guidelines for threading. Note that while
reviewing our threading charts, you can toggle between milled and turned options within
each tab to review the availability of threads for each method of manufacturing. All threads
need to be selected and saved before proceeding with an order. If you change your
manufacturing process or material at any point, please check the Thread Assignment tab
again as selections could change.

Many CAD packages allow you to display threaded features in a few different ways including
tap drill, cosmetic thread, or by the major diameter of the thread. We suggest selecting the
pilot diameter if it is designed at approximately 75% of the thread diameter.

On milled parts that require external threads, you must design the threads on your part as
this would then be in our standard milling procedure that uses ball and flat end mills. As CAD File Formats
stated earlier, this wouldn’t be the preferred method for producing threads as you may be
CAD files should be submitted in a file format other than .STL. We discourage
required to perform a secondary process of chasing a cutting die over the threads to ensure
uploading .STL file formats for machined parts because our software is unable
the parts can be assembled correctly.
to recognize features like pilot holes in that format. You should use a neutral
On turned parts, external threading improves greatly because the part is spinning on center file format such as .IGES or .STEP, if possible.
and a sharp single-lip threading tool can produce a quality thread. The design of an external
turned thread is like that of the internal hole. Remember that you must remove the threads so
our software can digitally view the outside diameter to determine the type of thread needed.

Definitive Guide to CNC Machining 24

Post-processing
Options
Perhaps you are wondering how to keep those 4140
steel parts you’re ordering free of rust. Maybe you want
your custom-made aluminum bicycle pedals to be a
beautiful shade of blue or make threaded parts more
durable. We can help you make CNC machined parts
perform better, make them more wear- and corrosion-
resistant, and improve their overall appearance, by
using various finishing options through our precision
machining offering.
Plating is Suitable for a Range of Materials
If you need a durable, corrosion- and wear-resistant finish, suitable for a wide variety of materials,
look no further than nickel plating. Multiple types are available. At Protolabs, we offer the two most
common. The first of these—bright nickel plating—is applied by negatively charging a workpiece
after submersion in a tank of electrolyte. Current is applied to a series of nickel anodes within the
tank, slowly releasing nickel ions that migrate through the solution and bond themselves to the part.

As its name implies, bright nickel is shiny. Depending on the amount of current applied and time spent
in the tank, thickness can range from 0.00005 in. to 0.001 in. (0.0013mm to 0.0254mm). Chances are
good that your old car's bumper is nickel-plated, as are the trim pieces on the dash, and the lighting
fixtures in your house. All are covered under SAE AMS QQ N 290, although other standards apply.
Electroless nickel plating eliminates the need for electrical contact and the subsequent electrical flow
just described. For this reason, it's a favorite for high-volume plating of fasteners, fittings, and other
hardware items. It is also very useful for hard-to-reach interior areas as it plates evenly across the part.
It can be applied to almost any substrate: steel, stainless steel, aluminum, brass, and others. Also, it
has excellent wear resistance compared to electroplated products.

Zinc, Tin, Gold, Silver, and Other Plating Options

The electroplating process can be applied to other metals, too. Exchange the nickel anodes for ones
made of zinc, for example, and you’re left with a plating that’s great at protecting iron and steel from
corrosion. Zinc should not, however, be used where parts will see temperatures greater than 500°F or
in marine environments. See zinc coating ASTM B633-15 for additional information.

Due to its low cost, tin plating is also quite common. It is a soft, ductile, silvery-white metal that is not
only corrosion-resistant but quite agreeable to soldering, so it is often used in the electronics industry
for computer chassis and other components. Hot dip tin plating is also possible, which together with
its electroplated alternative is described in MIL-T-10727 (MIL is a military specification coating).

Then there are gold and silver-plating options. From an electronics industry perspective, both are
like tin, albeit with higher conductivity, solderability, and corrosion resistance, but with a higher
price to match. And as evident from their use in the jewelry and dinnerware markets, they have an
attractive appearance. These and other metals may require that a “nickel strike” is applied to the
surface before plating to improve adhesion. Nickel plating provides excellent adhesion properties,
so it is often used as an “undercoat” for other coatings.

Definitive Guide to CNC Machining 26

Anodizing Looks Great
Anodizing is one of the most performed of all finishing options. Often referred to as a plating
operation, it’s technically an electrochemical conversion process that creates a thin oxide film
on a metal part's surface.

For this discussion, we'll focus on aluminum anodizing as covered under standard MIL-A-8625,
although anodizing of titanium and other metals is also possible. More on titanium shortly.

Three types of aluminum anodizing are available:

1. Chromic Acid anodize (Type I) provides a whisper-thin but still durable coating, typically
between 0.00002 in. and 0.0001 in. (0.00127mm and 0.00254mm) thick. It is gray in
appearance but can be dyed a dull, non-reflective black. It's commonly used as a primer
before painting. Like all anodized surfaces, it is non-conductive.

2. Harder yet is Type II Sulfuric Acid anodizing, also known as decorative anodizing for its
ability to absorb practically any color dye. That said, it offers an exceedingly durable and
attractive finish up to 0.001 in. (0.0254mm) thick. Everything from carabiner hooks and
flashlight handles
to motorcycle parts and hydraulic valve bodies can be Type II anodized.

3. Beyond this is Type III Hard Anodize, or Hardcoat. Its color ranges from dark gray to bronze-
like and is the thickest anodize available, adding as much as 0.003 in. (0.0762mm) to a part
diameter and twice that to threads. Typically, the dimensional impact of most coatings
and platings is fairly minimal, but Hardcoat is just the opposite, something you want to
remember when designing close-tolerance parts.

As mentioned, you can also anodize titanium components. Refer to standard Aerospace Material
Specifications (AMS), especially AMS 2487 and AMS 2488 for additional details. In the medical
industry, titanium medical devices are commonly anodized for color-coding purposes. In
aerospace applications, titanium parts are anodized for increased corrosion resistance.

One quick reminder about the use of military (MIL) and aerospace (AMS) standards for
anodizing and plating. If available, it’s always best to reference these and other applicable
specifications when ordering from us; otherwise, we might be left wondering what kind of
anodizing, etc. you are requesting.

Definitive Guide to CNC Machining 27

The table below outlines the three types of aluminum anodizing that are available. In either case, we offer dozens of color choices and sheens. Paint and powder coat alike can be made
glossy, flat, matte, or anything in between. Just let us know what you're looking for by using a Sherwin
Aluminum Anodizing Thickness Williams paint code or equivalent, as this provides us with all the information needed to get the job
done right. Color matching is generally not available, though for paint we may be able to color match.
Range between 0.00002 in. and 0.0001 in.
Chromic Acid (Type I)
(0.00127mm and 0.00254mm) Passivation Also Protects Parts
Finally, no discussion of plating processes would be complete without some explanation of
Sulfuric Acid (Type II) Up to 0.001 in. (0.0254mm) passivating, a process that “converts” the outer surface of metals to an exceedingly thin layer of
oxide. It is similar in this respect to anodizing, but it’s use is far more widespread, is applicable to
a wide variety of metals, and is mostly performed without electricity.
Hard Anodize (Type III) Up to 0.003 in. (0.0762mm)
Stainless steel is passivated to further reduce any chance of corrosion and remove any stray iron
from machining operations.
Keep in Mind Sealing After Anodizing
Alloy steels, previously plated parts, and aluminum are subject to conversion coatings, like chem-
With some exceptions, parts are usually sealed immediately after anodizing in a bath of nickel
film, and use phosphate or chromate to create the protective outer surface. These conversion
acetate or hot deionized water, closing off the material's microscopic pores. This process
coatings create an additional protective film for plated parts and some alloys. Chromate and other
also generates different performance characteristics such as improved bonding and lubricity,
chem-film coatings for aluminum have good corrosion resistance and are a great base for paint.
depending on the type of anodizing and sealing process used.

For mission-critical parts, be sure to discuss your application requirements with one of our
applications engineers before proceeding.

Powder Coating or Painting for Machining

Powder coating is another popular option. A staple of sheet metal fabricators (including
Protolabs), think of it as dry paint that can be applied to any electrically conductive metal.

This option works by spraying a polymer-based colored powder through a special gun that
charges the individual paint particles as they pass, making them stick to the surface. The powder-
coated part is then placed into a hot oven to cure.

Powder coating is thicker than traditional wet paint and is more durable and fade resistant as
well. It’s also better for the environment—any leftover powder can be reclaimed and reused, and
Grab a Surface Finish Guide
there are no smelly VOCs (volatile organic compounds) to contend with like there is with paint. Get an up-close look at your surface finish
For parts that can’t resist the heat of the curing process, however, or ones that require a thinner options for CNC machining at Protolabs.
coating than powder coat provides, paint is an excellent alternative.

Definitive Guide to CNC Machining 28

Complex
Features
CNC machining can create parts with incredible
complexity and accuracy, and do it at a reasonable
cost. The key is to design parts that adhere to certain
rules for complex features.
Plating is Suitable for a Range of Materials
CNC machine tools gain greater capabilities every year. Live-tool lathes can mill various
shapes and drill off-axis or radial holes, operations that would once have required a
1 Hole
Placement
The minimum size for on-axis and axial holes on Protolabs’ CNC lathes is 0.040 in. (1mm), with a
separate trip to the milling department. And some machining centers are equipped
maximum depth of 6x the diameter. Radial holes (those drilled from the side of the part) should be at
with indexing heads that support 5-axis machining, where multiple sides of a part can least 0.080 in. (2mm) in diameter. Holes that go all the way through turned or milled parts are usually
be completed in a single operation. This is good news for designer and engineer. Not okay (especially on hollow or tube-shaped parts), but depending on the part size, hole diameter, and
only can extremely complex parts be produced, but it can be done with greater quality, material, the cutting tool might not have enough reach. Protolabs will machine from each side, when
lower cost, and shorter lead times. possible, but be sure to check your design analysis for potential constraints.

2
As with our milling centers, CNC turning on high-speed lathes can complete many
Deep
complex parts in a single operation. Live tooling and Y-axis capabilities mean it’s Features
possible to turn a bolt, mill the wrench flats, then drill a cross hole for a safety wire.
External grooves on a turned part cannot exceed 0.95 in. (24.1mm) in depth or be narrower than 0.047 in.
More complex examples might include a hydraulic piston with alignment slots on one
(1.2mm). All other slot-like milled features generally read from the same playbook as drilled holes in terms of
end, a fitting with spanner wrench holes on its face, or a shaft with an external keyway.
size, but a good rule of thumb is to keep the depth less than 6x the feature width. Also, be sure to leave at
In some cases, it’s even possible to turn a part that’s more orthogonal than it is round.
least 0.020 in. (0.5mm) wall thickness on the adjacent material. Large flats and other milled surfaces—mill
But that doesn’t mean anything goes—certain machining rules still apply—and not or lathe—depend entirely on the part geometry relative to the available cutter size. Deep ribs and grooves
following them can lead to expensive reworks and project delays. With that in mind, can be challenging though, wherever they’re made. It is possible to cut heat sink-like features on a turned

here are five elements to consider when designing complex parts. or milled part, but this depends on the actual part geometry and available tools. Again, check your DFM
analysis carefully, and don’t be afraid to try our software, or contact an applications engineer.

True 5-Axis Machining

Protolabs’ extensive machining capabilities include 5-axis mills, which
allow for simultaneous movement on up to five machine axes while the
cutting tool is engaged in the workpiece. Complex “swept surface”
parts like boat propellers, orthopedic implants, and turbine blades can Adding Threaded Features: Designers frequently add Coil Inserts: Considering threading for your machined
threaded features to milled and turned parts. Threading part? You might also think about using an insert. Coil inserts
now be manufactured with fewer setups. options differ for each, so check here to ensure the right (shown here), and key inserts, provide longer service life
process is selected. than bare threads, especially in soft materials like aluminum
or plastic.

Definitive Guide to CNC Machining 30

3 Better
Threads
There’s a great deal of overlap in threading capabilities between Protolabs’ turning and milling
centers. Protolabs can thread from #4-40 (M3 x 0.5) up to about 1/2-20 (M10 x 1.25) depending on
the type of machine and the feature placement, although some exceptions exist. Check out the
threading options for precise measurements and details. Also, remember what you read earlier
about the proper way to model threads, and how this relates to internal vs. external and milled
vs. turned part features. You might also think about using an insert. Coil and key inserts provide
longer service life than bare threads, especially in soft materials like aluminum or plastic, and are
easy for you to install.

4 Texting
Can Be Costly
Complex aerospace and medical parts often require permanent marking of part numbers
and company names. Recessed text may look nice, but it’s also a very time-consuming
machining operation and is downright prohibitive as production quantities rise. It’s better to
electrochemically etch or laser-mark parts, but if you must have engraved text, keep it short with
simple, clean fonts. For soft metals and plastic, we recommend Arial Rounded MT font 14 point
0.3mm deep, and for hard metals opt for Arial Rounded MT font 22 point 0.3mm deep.

5 Radii:
Watch the Corners
One common mistake on any machined part is the call out of sharp internal corners. For example,
the turning tools typically used for finishing at Protolabs have a 0.016 in. (0.032mm) nose radius,
so any mating parts should be designed with this in mind. Milling cutters go down to 0.040 in.
(1mm), which means any pockets will contain internal corner radii a little more than half that.
That’s pretty sharp but remember that milling with a tool that small takes a long time, and will
be limited to a pocket no more than 0.375 in. (9.52mm) deep. Instead, relieve internal corners or
allow for as large an internal radius as possible on mating part designs.

Definitive Guide to CNC Machining 31

High-volume
Machining
You already know that CNC machining at Protolabs is
different from traditional manufacturing. Our process is
fully automated—from CAD analysis to auto-toolpathing
and digital inspections. This automation is what enables
our speed, and you can take advantage of that speed when
you're ready to move to higher volume production or simply
need more than 15 prototypes.
 Machining for Higher-volume Needs Emerge
At Protolabs, we saw a way to fill the production-quantity gap, and also solve upfront and
warehousing cost issues. Our massive machining capacity—with more than 500 CNC
machines—can mill or turn parts in as fast as a day for rapid prototyping, or low-volume, end-use
part production. This brings down machining costs without adding to lead time.

Production machining also helps ensure part quality with FAI reporting, Certificate of Compliance
(CoC) documentation, and certifications such as ISO 9001 and AS9100.

Production machining doesn’t offer the same economies of scale as molding or casting
processes—especially at high-volume levels (think tens of thousands or millions). However, as
machined production volume increases, cost per part goes down (think low-volume runs of
dozens to a few thousand). Production machining also solves warehousing and inventory issues,
providing you with supply chain flexibility by producing parts on-demand. In many cases, our
customers find our machining service now allows them to use a single-source supplier from
concept validation to short-run production.

Machining for Production Provides Supply Chain Flexibility

Plenty of machine shops out there can produce machined parts. We have several key
advantages, particularly when you need production volumes of parts relatively quickly, or even
varying quantities of parts. With our capacity, we can produce higher volumes of parts faster
than other shops. Our end-to-end process begins with design analysis and quotes. Upload a
CAD model to get your free analysis and quote within hours. If you need prototypes, request
a quick-turn quote and get finished parts in as fast as one day. When you’re ready for a higher
volume of production parts, request a production quote and get parts in as few as five days.
Our capacity, plus our large stock of materials, allows this speedy turnaround. The entire
production process, from toolpath development to machining to finishing, is handled in-house
for maximum speed, quality, and process control.

Related to flexible quantities, leveraging machining eliminates the high initial costs of mold or die
production. Once the toolpath has been developed, you can order machined parts in lots as small
as 15 pieces. On the other hand, if your ultimate production volume will be high enough to justify
molding or casting, you can use machining for bridge production and take your product to market
Our massive machining capacity, which mills or turns parts in as fast as a day for rapid prototyping, can also be
used for low-volume, end-use part production. while you wait for production molds or dies to be made.

Definitive Guide to CNC Machining 33

Production Machining of Plastics
At volumes of a thousand or fewer, machining plastics can be less expensive than injection
molding. In addition, machining can produce parts that would be difficult to mold. These include
parts with uneven wall thicknesses or with wall thicknesses over 0.150 in. (3.81mm), often needed
for parts used as fixtures or wear plates.

The overall speed advantage of machining versus injection molding at modest production
volumes increases as parts increase in size. Also, machining plastic eliminates sink, warp, and knit
lines you find in molded parts, and machined parts don’t require draft.

In some cases, engineers might consider 3D printing for these production volumes, but machined
parts are cut from solid billet, which gives them several advantages over 3D-printed parts.
Because they aren’t layered, machined parts may have better physical integrity than printed parts.
They can be cut from materials that cannot be used by 3D printers, and they can be machined to
smoother finishes than printed parts.

Our earlier chapter on materials for machining provides a rundown of the materials we offer.

Production Machining of Metal

At low- to medium-production volumes, machining of end-use metal parts offers significant
advantages over die casting. As with plastics, at appropriate volumes, machining is faster and
less expensive than casting.

While machining can begin turning out parts immediately, die casting requires the production of
hardened steel tooling, which is a slow and costly process.

There are more metals that can be machined than can be die cast. And die casting leaves a rough
surface like that found on cast iron cookware. Such surfaces can be smoothed by machining, but
this is a time-consuming secondary process.

Die casting also does not produce as solid a finished product as the billet stock used in machining.
Die cast metal can be porous, brittle, and subject to elongation. For these reasons, machining
may still be preferable to casting even when casting has a cost advantage.

As mentioned before, our earlier chapter on materials for machining provides a rundown of the
materials we offer.

Definitive Guide to CNC Machining 34

Why Protolabs for
Custom CNC Machining?
Fast and Reliable Delivery Infinite Capacity
Quickly iterate part designs and accelerate product Eliminate downtime spent waiting for parts and safeguard
development with quick-turn parts. Our automated design in-house machining with on-demand relief and infinite
analysis will help spot any difficult to machine features before manufacturing capacity.
your design is sent to the manufacturing floor, saving you from
Material Selection
costly reworks further into the product development cycle.
We stock more than 40 engineering-grade plastic and metal
Manufacturing Analysis and Online Quotes materials that are suitable for various part applications
When you upload your 3D CAD file to request a quote, we'll and industries. Materials range from plastics like ABS,
analyze your part geometry to identify any features that may polycarbonate, nylon, and PEEK to aluminum, stainless steel,
be difficult to machine, such as tall, thin walls or holes that titanium, and copper.
cannot be threaded.

Domestic Production and Support

Work with a trusted U.S.-based manufacturer and eliminate the If you have any questions regarding your quote or
risk of sending parts overseas. You can also call or email us at design, talk with our applications engineers who can
any time and we'll help with ordering parts, design feedback,
help guide you through the process. We look forward
material recommendations, and answer any questions.
to working with you on your next project!

Definitive Guide to CNC Machining 35

Contact Us
5540 Pioneer Creek Dr.
Maple Plain, MN 55359
United States

P 877-479-3680
F 763-479-2679
E customerservice@protolabs.com

Get an interactive CNC machining quote

within hours that includes real-time pricing
and free design for machinability feedback.