7 Ways to Reduce CNC Machining Costs

Learn how to reduce CNC machining costs without sacrificing your part’s quality.

CNC machining is an invaluable manufacturing process for creating precise and complex parts. One of its main benefits is that this technology can be very cost-efficient, especially when the important factors influencing CNC machining costs are understood and the right strategies are deployed to keep costs down.

This article will show how to reduce costs while fulfilling your part’s functional requirements. At MakerVerse, we work with companies of all sizes to help them reliably source CNC machined parts. These insights come from extensive cooperation with our customers and long experience in manufacturing.

Let’s get started with the different ways to reduce CNC machining costs.

Understanding CNC Machining Costs

CNC machining costs can vary significantly depending on several factors, including the type of material, size, quantity, complexity, and machine type used. Understanding these factors is crucial to optimizing CNC machining costs and ensuring your project stays within budget. To understand the costs involved, it is advisable to request a quote from reliable CNC machining service providers.

Factors Affecting CNC Machining Costs

Several factors can affect CNC machining costs, including:

• Material Selection: The type of material used can significantly impact the cost of CNC machining. More rigid materials like stainless steel or titanium are more challenging and may require specialized tools and equipment.

• Design Complexity: The complexity of the design can also impact CNC machining costs. Intricate designs may require more advanced machinery and specialized tools, increasing costs.

• Production Volume: The number of parts produced can also impact CNC machining costs. Higher volume orders often have a lower per-unit cost due to economies of scale.

• Labour Costs: Labor costs, including the expertise and time of engineers, programmers, and machine operators, contribute to the overall cost of CNC machining.

• Machine Operating Time: The longer a part takes to machine, the more expensive it will be. Factors like part complexity and material hardness influence the time it takes to operate the machine, thereby affecting machining costs.

1. Standardize Whenever Possible

Using widely available materials and off-the-shelf parts gives you the benefits of mass production, even in small-batch production, which can significantly reduce machining costs.

• Some of the other benefits of using standard components include:

• Simplified inventory management

• Easier purchasing

• Avoiding tooling and equipment investments

• Faster manufacturing cycles

Standard components can be used to handle tasks such as inventory management and purchasing more efficiently, leading to cost savings.

2. Simplify Product Designs

When ordering several similar items, having identical sides and parts with multiple uses will be the least expensive. Standardizing designs will provide economies of scale for production, simplify manufacturing processes, and reduce the investment needed for tooling and equipment. Avoiding design features like sharp internal corners can simplify the manufacturing process and reduce machining time and costs.

Design optimization is critical to reducing CNC machining costs. It involves simplifying the design and minimizing the number of operations required in the machining process.

Design Optimization for CNC Machining

Design optimization is critical to reducing CNC machining costs. By simplifying the design and minimizing the number of operations required, you can reduce the time and effort needed to machine the part. This can be achieved by:

• Removing Unnecessary Features: Simplify the design by eliminating features that do not add value to the part’s functionality.

• Using Standard Tool Sizes and Tolerances: Standardizing tool sizes and tolerances can reduce the need for custom tools and minimize machining time.

• Optimizing Part Layout: Arrange parts within the raw material to minimize waste and reduce material costs.

• Considering Alternative Manufacturing Methods: Explore other manufacturing methods, such as precision stamping or sheet metal fabrication, which might be more cost-effective for specific designs.

  • Evaluate the necessity of surface treatments like chemical film, which can enhance component properties but also increase machining costs.

Design for the Most Cost-Effective CNC Machining Process

Each manufacturing technology has its advantages and disadvantages. During the design phase, you can utilize these advantages to reduce costs. Innovative designers will learn the unique characteristics of each manufacturing process and then take advantage of them.

Choose the most cost-effective option if your design is manufacturable via multiple technologies.

The different CNC technologies, from most cost-effective to least, are:

• Laser cutting

• Turning

• Milling 3-Axis

• Turn-milling

• Milling 5-Axis

The expected production level is an essential consideration in the design, as specific manufacturing processes are better suited for small-batch or large-scale production. 3D printing, for example, is usually best for low batch sizes (< 10), while injection molding can be best for large batch sizes (>1,000).

Careful selection and maintenance of machine tools are essential to minimize expenses associated with adding new tools when existing ones fail.

4. Be Liberal with Tolerances

The extra costs associated with too-tight tolerances in CNC milling are well documented but worth repeating. The higher costs of tight tolerances stem from:

• Extra operations, such as grinding or polishing after primary machining operations

• Higher tooling costs stemming from the greater precision needed when making tools, plus more frequent maintenance needs as they wear

• Longer operating cycles

• Higher scrap and rework costs (See below chart)

• The need for more skilled and highly trained workers

• Higher materials costs

• More sizable investments are needed for precision equipment

• Tool wear and breakage: Tight tolerances can lead to increased tool wear and breakage, resulting in higher replacement costs and longer machining times.

5. Choose the Right Material

The MakerVerse platform offers over 100 CNC machining materials, including various polymers and metals. Selecting the best material for your CNC machining project is crucial. Each material has its uses, so choosing the best material that delivers performance at a reasonable cost is vital. In addition to machining fees, the raw material cost is a significant component of the overall expenses for CNC machined parts.

There is no single material that is best for saving money. In the long run, the most economical material meets the part’s specifications while offering the lowest combined cost of materials, processing, and service over the product’s lifespan.

7. CNC Machine Selection and Costs

Choosing the right CNC machine for your needs is critical to optimizing CNC machining costs. Different types of CNC machines have varying fees, and selecting the right machine can help reduce costs and improve efficiency.

Consider the start-up costs, including initial expenses related to CAM programming and process planning, which can be significant but diminish with higher production volumes.

Choosing the Right CNC Machine for Your Needs

When selecting a CNC machine, consider the following factors:

• Type of Material: Different materials require different types of CNC machines. For example, harder materials like stainless steel or titanium may require more advanced machinery.

• Design Complexity: Intricate designs may require more advanced machinery and specialized tools.

• Production Volume: Higher volume orders often require more advanced machinery to meet demand.

• Budget: Depending on the type and complexity of the machine, CNC machines can cost from $20,000 to over $150,000.

By considering these factors and selecting the right CNC machine for your needs, you can optimize CNC machining costs and improve efficiency.

6. Avoid Secondary Operations

The various operations associated with CNC machining can drive up costs. That’s why it’s always best to design your part to avoid secondary operations as much as possible. Deburring, inspection, plating, painting, heat treating, material handling, and other processes can add up to more than the main manufacturing cost. Therefore, these processes should always be considered in the design phase. For instance, bead blasting can be a cost-effective surface finishing option, but it should be used judiciously to avoid unnecessary expenses.

7. Work with the Right Manufacturing Team

Teamwork is essential in any line of work, and that’s especially true for CNC machining projects. Work with the manufacturer and ask if you have any doubts about the design. After all, getting the design wrong adds to costs.

Similarly, let the manufacturing team focus on what they do best. On drawings, specify only the final characteristics needed; do not specify the process. Allow manufacturing engineers as much latitude as possible in choosing a process that produces the required dimensions, surface finish, or other required characteristics.

With MakerVerse, our design and engineering experts check the manufacturability of your design. After, a fully-vetted supply chain ensures you get the high-quality parts you need.

For sophisticated production orders, experts will work with you to develop, align, and supervise a manufacturing and quality plan from start to finish – keeping you updated at every step.

Other Points to Consider

Labor Costs of CNC Machining (CNC Machinist Salary)

Labor costs are a significant component of CNC machining expenses. Skilled operators are essential for setting up, programming, and running CNC machines efficiently. Labor costs can vary depending on the complexity of the project and the level of expertise required. Balancing the need for skilled labor with budget constraints is key to managing machining costs effectively.

The cost of labor for CNC machining can range from $25 to $50 per hour, depending on the location, experience, and qualifications of the machinist. In addition to the hourly rate, labor costs can also include benefits, training, and overhead expenses. To minimize labor costs, manufacturers can consider outsourcing CNC machining operations to countries with lower labor costs or investing in automation technologies that reduce the need for manual labor.

Machine Operating Time and Labor Efficiency

Machine operating time is a critical factor in determining labor costs. The longer a machine takes to complete a task, the more labor hours are required, and the higher the labor costs. To improve labor efficiency, manufacturers can invest in high-speed CNC machines, optimize machining processes, and implement lean manufacturing techniques. By reducing machine operating time, manufacturers can minimize labor costs and improve overall productivity.

Production Volume and Economies of Scale

Production volume is a significant factor in determining CNC machining costs. Higher production volumes can lead to economies of scale, reducing the cost per unit. However, higher production volumes also require more material, labor, and equipment, which can increase overall costs. To optimize production volume, manufacturers can consider outsourcing CNC machining operations to contract manufacturers or investing in automation technologies that enable high-volume production.

Volume of Production and CNC Machining Costs

The cost of CNC machining can vary significantly depending on the production volume. For small production runs, the cost per unit can be high due to setup costs, material waste, and labor costs. However, as production volumes increase, the cost per unit decreases due to economies of scale. To minimize CNC machining costs, manufacturers can consider producing larger quantities, optimizing machining processes, and implementing lean manufacturing techniques.

By understanding the factors that affect CNC machining costs, manufacturers can optimize their production processes, reduce costs, and improve overall efficiency. By considering labor costs, production volume, and economies of scale, manufacturers can make informed decisions about their CNC machining operations and stay competitive in the market.