The Guide to CNC Machined Aluminum Parts

What makes CNC machining so great? One of the main reasons is the vast selection of materials, including aluminum CNC machining, which offers high accuracy, corrosion resistance, and the ability to create complex geometries. 

Aluminum is one of the most popular materials. Lightweight, robust, and relatively inexpensive, almost every industry uses CNC-machined aluminum parts and other aluminum products.

Learn all about the benefits, the most popular alloys, the best finishes, and more to ensure your next project succeeds.

Aluminum has long held a prime position in various industries, from aerospace to electronics. The aerospace industry, in particular, relies on aluminum for manufacturing lightweight and high-strength components that are crucial for structural applications. But what makes it a preferred choice for the CNC machining manufacturing process?

Lightweight yet strong: Aluminum exhibits a remarkable strength-to-weight ratio. This benefit is critical for applications where weight savings are essential without compromising structural integrity.

Excellent thermal and electrical conductivity: This makes aluminum the material of choice for heat sinks and several electronic components.

Excellent corrosion resistance: An inherent oxide layer forms on aluminum surfaces, shielding them from corrosion. The appropriate finishes increase this corrosion resistance, making it suitable for environments prone to corrosion, such as marine applications.

Ease of machining and finishing: Aluminum’s malleability and softness allow it to be machined at high speeds, which means less energy and time than harder metals.

Cost-effectiveness: Aluminum’s abundant availability and ease of machining often result in competitive prices for CNC-machined parts. It’s a budget-friendly choice for both large-scale and small-batch projects. To see just how cost-effective aluminum is, try out MakerVerse’s instant quoting.

Various CNC machines, including milling, turning, and drilling machines, are employed to produce high-quality aluminum parts. Various machining processes, such as CNC machining, drilling, turning, and milling, are employed to produce high-quality aluminum parts, underscoring the broad applicability and efficiency of these techniques in the industry.

Not all aluminum is treated equally. Various aluminum alloys amplify specific characteristics of aluminum, tailoring them to different applications. Some of the most machined aluminum alloys:

Aluminum 6061: This alloy combines strength, weldability, and corrosion resistance.

Aluminum 6060: Slightly softer than 6061, this alloy is known for its formability and weldability. It’s commonly used in intricate extrusions and fittings.

Aluminum 5083: With superior resistance to corrosion, especially in seawater, 5083 is a primary choice for marine applications.

Aluminum 7075: Boasting impressive strength, 7075 is ideal for high-stress applications where strength is paramount. It is often heat treated to enhance its strength.

Aluminum 6082: A structural alloy, 6082 balances strength, and corrosion resistance. It is used in highly stressed applications, including trusses, cranes, and bridges.

For engineers and designers, the nuanced differences between these alloys can dictate the success of a project. Our experts can help you make the right choice on the MakerVerse platform.

While aluminum offers unique advantages, there are some considerations to make if you manage the machines yourself during aluminum machining. Unlike cast aluminum, which is known for its cost-effectiveness and versatility, machined aluminum offers unique advantages in precision and durability.

Avoiding Material Welding onto the Cutting Tool: Aluminum is known to be “sticky” during machining. This stickiness can cause the material to weld onto the tool, especially at high speeds. To avoid this, ensure proper tool coatings like titanium carbonitride (TiCN) and use suitable coolants to dissipate heat and prevent material buildup.

Ensuring Precision and Reducing Tool Wear: The adhesive nature of aluminum can accelerate tool wear, impacting precision over extended runs. Use carbide tools or diamond-tipped ones to enhance tool life and maintain accuracy.

Addressing the Softness and Malleability of Aluminum: While aluminum’s softness makes it easier to machine, it’s also prone to deformities, especially when clamped improperly. To maintain the part’s integrity, ensure proper work-holding fixtures and avoid excessive force.

Beyond aesthetics, finishes can enhance a part’s wear resistance, electrical conductivity, or thermal properties depending on the application.

At MakerVerse, some of the most popular finishes for CNC-machined aluminum parts include:

Anodizing: Increases wear and corrosion resistance while offering various color options.

Powder Coating: Provides a durable, uniform surface finish with various colors.

Sandblasting: Achieves a matte, uniform appearance and can also prep surfaces for further finishing.