CNC Machining Services

Computer Numerical Control (CNC) machining is a manufacturing technique that uses computer programs to control machine tools. CNC machining produces precise, repeatable results from raw materials with complex cuts and intricate shapes. We explain CNC machining in detail, from the materials used to the processes involved, in our detailed blog post here. Read through it and learn everything you need to know.

CNC machining costs can vary depending on factors like the material you choose, the surface finish, the quantity, and the equipment used. The average cost per hour to run a 3-axis CNC machine is about $40. Keep in mind that the machinist’s salary cost will be added on top of that, so you’re looking at $80 to $100 per hour. A more sophisticated 5-axis machine can cost up to $200 per hour. Material costs will be added to that. It’s best to get a free quote on your specific project for a professional, accurate cost estimation.

CNC machining is a precise and automated manufacturing process that begins with designing a 3D CAD model. This model is converted into a CNC program, guiding the machine to execute specific tasks like cutting, drilling, or milling. The process follows these key steps:

• Design CAD Model: Create a detailed part design using CAD software.
• Convert CAD File to CNC Program: The design is converted into a G-code, directing the CNC machine’s actions.
• Prepare CNC Machine and Tools: Set up the CNC machine and select the necessary tools.
• CNC Machining Operations: The CNC machine performs precise machining operations to shape the part.

Our machining capacity includes a wide range of capabilities, ensuring we can meet the needs of various industries like aerospace, automotive, and medical. Here’s a breakdown of our key machining capabilities:

• Precision Tolerances: We can handle a variety of part sizes, from small precision components to large and complex parts. Our maximum machining size is typically 1200mm x 800mm, though it can be adjusted based on equipment configuration and customer needs.
• Machining Materials: We work with a variety of materials including metals (aluminum, steel, titanium), plastics, and composites.
• Multi-Axis CNC Machines: Our CNC machines operate with multiple axes (typically 3, 4, or 5 axes) for complex geometries and intricate part designs.
• High Volume and Custom Orders: Whether it’s large-scale production or custom, one-off prototypes, we have the flexibility to handle both.
• Threading and Cutting: We specialize in producing threads, holes, and cuts with high accuracy, tailored to client specifications.

Yes, we provide a full range of post-processing services! Our post-processing services include but are not limited to:

• Deburring: Removing sharp edges and burrs to improve safety and part functionality.
• Polishing and Surface Finishing: Achieving the desired surface texture and finish, whether it’s matte, gloss, or specialized coatings.
• Heat Treatment: Enhancing the material properties for added strength, hardness, or corrosion resistance.
• Anodizing or Coating: Providing additional surface protection or aesthetic finishes such as anodizing or powder coating.
• Assembly: If required, we can also handle part assembly to meet your specific requirements.

These ensure your products meet design specifications and possess excellent appearance and durability.

We ensure machining quality through a combination of advanced technology, rigorous processes, and detailed quality control standards. Here’s how we maintain high machining quality:

• Precision Equipment: We use state-of-the-art CNC machines and cutting tools that ensure high accuracy and consistency in every part produced.
• GD&T Standards: We apply Geometric Dimensioning and Tolerancing (GD&T) to guarantee precise part dimensions and fit, meeting strict industry standards.
• Inspection and Testing: Every part undergoes thorough inspection, including dimensional checks, surface finish evaluation, and functionality tests. We use advanced measurement tools like CMM (Coordinate Measuring Machines) and laser scanners.
• AQL and Sampling: Our quality control is based on Acceptable Quality Limits (AQL) and systematic sampling to detect any potential defects early in the production process.
• Experienced Technicians: Our skilled machinists are experts in reading blueprints and executing complex machining tasks, ensuring parts meet all specifications.
• Traceability and Documentation: We maintain complete and accurate quality documentation, including First Article Inspection (FAI), metallurgical testing, and computerized maintenance logs, ensuring full traceability.

Yes, we provide sample machining services, allowing you to verify the design, functionality, and quality before mass production. Our team can create prototypes or small batches based on your specifications, allowing you to test materials, machining processes, and ensure your parts meet the required standards.

Our pricing and quotes are calculated based on several factors to ensure we provide the best value for your specific needs. Key factors include:

• Material Type: Different materials, such as metals, plastics, or composites, have varying costs based on availability, complexity, and required machining processes.
• Part Complexity: The complexity of the design, including the number of features, geometric shapes, and machining operations required, influences the overall cost.
• Quantity: Larger production runs often result in lower per-unit costs due to economies of scale, while one-off prototypes or small batches may carry a higher cost per part.
• Machining Time: The time required to complete each part, including setup, cutting, finishing, and inspection, affects pricing. More intricate designs take longer to machine.
• Tolerance and Quality Requirements: Higher precision and stricter tolerances may require advanced equipment and more time, impacting the price.
• Post-Processing Needs: If additional services like deburring, polishing, heat treatment, or coating are required, these will be included in the quote.

Once we assess these factors, we provide a detailed, customized quote that ensures fair pricing based on your specific project requirements. For more information, feel free to reach out!

At Kemal, we offer Design for Manufacturability (DFM) feedback to help optimize your design for CNC machining. Our engineering team reviews the design’s feasibility and offers suggestions to improve manufacturability, reduce production costs, and increase machining efficiency.