At Accurate CNC, we work on many types of projects, and every part comes with its own set of requirements. Those requirements can introduce challenges that make a component more difficult to manufacture, often leading it to be classified as a “complex part.
Complex part manufacturing is never straightforward. Part complexity can result from a variety of factors, including material, tight tolerances, intricate features, or an incomplete design.
Here’s how we approach challenging components so our customers can expect accuracy even when their requirements introduce obstacles.
Material Behavior Can Add Complexity
When a new project comes in, the first thing we do is review the material requirements.
We check to see if we have it readily available in-house or if it requires ordering.
Because we work on a variety of project types, we have experience with a wide range of materials, and we know material behavior can often create unexpected complexities in manufacturing.
One example is foam. A foam part might look simple on a drawing, but when you cut foam, it vibrates. This can cause imperfect edges or even cause the part itself to snap in half.
Plywood presents its own challenges. During machining, a chunk of material can sometimes break away from the part. And plastic can curl or change shape over time.
This is why the material itself can influence how a part is approached. A design that appears straightforward may require a different precision machining strategy once the material is considered.
Tight Tolerances Can Change the Manufacturing Approach
After analyzing material requirements, our team next reviews tolerances.
Our precision machine shop uses a couple of general guidelines to help us determine how a component will be manufactured.
Components with looser tolerances (such as ±0.010”) and relatively simple features may be well suited for the router.
Parts with tighter tolerances or more intricate features, like deep holes, may require CNC milling.
When a tolerance reaches ±0.005” or tighter, our team takes a closer look at the tooling and setup to make sure the planned approach is appropriate.
That review can also lead to a conversation about why a particular tolerance is needed.
After discussing the part’s intended function, we often realize the application allows some tolerances to be relaxed. Loosening tolerances when appropriate can simplify manufacturing and potentially reduce cost and production time.
The goal is to understand what the part needs to do and make sure the specifications support that function.
An Incomplete Design Can Make a Project More Challenging
Walk-in customers and one-off projects typically start with a sketch or drawing that needs to be developed further. When a CAD model isn’t provided, we design the part in CAD ourselves, and a project becomes more challenging from the beginning.
First, we make sure we understand exactly what the finished component should look and function like.
Once we understand the customer’s requirements, we develop a manufacturable design that our machinists can work with.
Complex geometries can add another layer of difficulty. Features such as deep holes and other intricate details can affect which tools and machining strategies can be used.
Software Helps Us Identify Potential Challenges
With a 3D CAD model, Paperless Parts can help us identify potential manufacturing issues before production. Mastercam then helps our team develop and verify the machining approach for complex geometries.
When a part requires design changes before being manufactured, we can collaborate with you to determine another way to accurately manufacture the part with our available tooling and equipment.
Complexity Looks Different on Every Part
Every day brings new challenges to Accurate CNC, and every part can have its own source of complexity.
Material selection, tight tolerances, difficult-to-machine geometries, or an incomplete design can all make a component more challenging to manufacture. Our Idaho machine shop works through the details with our customers to understand those challenges and how to produce the part accurately and efficiently.
If you’re looking for a manufacturing partner for your next complex project, request a quote from Accurate CNC today, and let’s work through the details together.