Designing for Low-Cost Machining

Introduction

Good machining starts before the first tool enters the material.

The geometry of a component determines how it can be fixtured, which tools are required, how many setups are needed, and how long production will take.

Deep pockets

Deep pockets may require specialized tooling and additional machining passes.

Where possible, design pocket depths around readily available cutting tools.

Internal corners

Sharp internal corners can be difficult to machine because most cutting tools are round.

Adding appropriate internal radii can reduce machining time and improve tool life.

Tight tolerances

Not every dimension needs the same tolerance.

Reserve tight tolerances for functional features and allow more practical tolerances elsewhere.

Thin walls

Thin sections can introduce vibration and deflection during machining.

Increasing wall thickness where the application allows can improve both manufacturability and part stability.

Multiple setups

Parts requiring several orientations often require additional setup and inspection time.

Designing features that can be accessed from fewer directions can simplify production.