Manufacturing Custom T-Slot Chain Guides: Why We Use a Router Instead of a Mill
T-slot parts are structural rails manufactured from aluminum, steel, or durable plastic, featuring a “T”-shaped groove running down their length. These versatile parts have numerous applications across industries, but within industrial manufacturing environments they are especially common as chain guides within assembly line conveyor systems.
While many T-slot parts are manufactured from extruded aluminum, achieving the highest precision for these parts usually requires CNC milling. However, this process can be costly and, for long chain guides, quite inefficient.
But at Accurate CNC, we take a different approach and use a router instead of a mill. With this method, we’re able to manufacture T-slots precisely and efficiently, reducing costs and lead times for our customers.
Routing T-Slots for Fast and Efficient Production
The standard method for manufacturing precision T-slot parts is to use a CNC mill and manufacture them one at a time. This is great for small T-slot parts, as it’s fast and efficient.
However, for long T-slot parts like industrial chain guides, this process becomes impractical. CNC mills can only cut lengths of about three feet in one setup, so milling long T-slot parts can require three or four different operations. Additionally, due to length, parts can begin to “walk” during milling, resulting in imprecise cuts and out-of-spec tolerances.
Through trial and error—and a lot of broken tools—we found a better approach: using our routers to cut long T-slots. This approach allows us to manufacture T-slots with a single setup and prevent walking while cutting a full sheet of parts simultaneously. Not only does this minimize material waste and reduce the potential for rework, but it also significantly streamlines production for cost-effective results.
A Real-World Example: Custom T-Slot Chain Guides for High-Wear Applications
One of our long-time customers in the industrial packaging industry recently approached us as they were refurbishing their packaging machines. They needed new custom T-slot chain guides—each six feet long—to ensure their equipment would operate effectively and efficiently for years to come. Given the high-wear operating environment, UHMW—a durable, low-friction plastic—was the ideal material for the application instead of aluminum or steel.
With our unique approach to routing T-slots, we were able to manufacture 14 parts with a single setup and reduce both costs and lead times for our customer. As a result of the quality and efficiency we were able to achieve, we’ve become their primary supplier for custom T-slot chain guides.
How We Overcome the Toughest Challenges in Routing T-Slots
While we’ve become experts at routing T-slots over the years, the process does present challenges. But overcoming difficult manufacturing problems is one of the things we do best here at Accurate CNC, and it’s one of the reasons why our customers value our partnership for so many of their manufacturing needs.
Determining the Correct Toolpaths
One of the biggest challenges with using a router instead of a mill to manufacture T-slots is determining the correct toolpaths to manufacture a full sheet of nested parts in one setup.
On a mill, CAD/CAM software can make this process relatively simple. But when you have a full sheet of parts on a router, you need to be sure not to overextend your geometry, or the router can cut into adjacent parts or become trapped in the undercut without an exit path.
To overcome this, we developed a clever workaround: creating a “dummy geometry” where the T-slot cutter moves back into a pocket within the part with enough clearance to be removed cleanly. This allows us to closely nest parts, reduce material parts, and improve throughput.
Ensuring Functional Tolerances
Chain guides require tight tolerances to allow a chain to move smoothly. However, tolerances that look great on paper can sometimes result in parts that are, in fact, too precise due to complex tolerance stack-ups.
To ensure functional tolerances and real-world performance, we use a simple but effective technique: go/no-go testing. While parts are still on the router table, we fit and run chains that customers provide through each guide.
If the chain fits and runs smoothly, the part is good to go. If not, we can make small adjustments on the spot—no need for additional setups or rework.
Accurate CNC: Your Source for Custom T-Slot Chain Guides
If you need T-slot parts for any application, our CNC routing services provide an efficient and cost-effective solution.
But we don’t only manufacture T-slot parts at Accurate CNC—in our Idaho machine shop, we leverage a broad range of capabilities to provide a full range of manufacturing services.
Whether you have parts that require precision machining or need to leverage our CNC router services to manufacture your custom designs, reach out and request a quote to discuss what we can do to meet your needs.