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CNC machining is a great help for prototypes

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CNC machining  prototype

In the design process of R&D products, after they have finished the design illustrations, among things they want to do most is to recognize what the products they make resemble in reality, and also whether the appearance of the products follows their own layout ideas., Is the framework style of the product affordable, etc? Prototype production is produced in feedback to this need.

Category of prototypes:

Prototypes can be split into handbook as well as numerical control models according to the manufacturing methods:

Hand-operated model: The primary workload is done by hand.

CNC machining prototype: The primary work is completed by CNC equipment tools, and also depending upon the devices utilized, it can be divided into laser fast prototyping (RP, Rapid Prototyping) models as well as machining center (CNC) prototypes

A: RP model: mostly produced by laser rapid prototyping modern technology.

B: CNC model: mostly generated by machining facility.

 

RP models have their own benefits compared with CNC models: the benefits of RP models are primarily in its rapidity, however it is generally formed by piling modern technology, so RP models are typically fairly harsh, and also there are specific demands for the wall surface density of the item, for instance, If the wall surface density is too thin, it can not be generated.

 

The benefit of CNC machining prototype is that it can properly mirror the details revealed in the drawings, and the surface area top quality of CNC model is high, especially after the surface spraying as well as silk printing are completed, it is much more glamorous than the product produced after the mold and mildew is opened. For that reason, CNC model production has increasingly end up being the mainstream of model production.

 

According to the materials made use of in production, prototypes can be split right into plastic as well as metal prototypes:

( 1) Plastic cnc machining prototypes: The raw products are plastic, mostly for models of plastic items, such as televisions, monitors, telephones, and so on.

( 2) Metal cnc machining prototypes: The raw products are aluminum-magnesium alloys and also other metal products, mainly for high-end products, such as laptop, high-end single gamers, MP3 players, CD players, and more.

 

The need of prototype production

( 1 )Design examination

The prototype is not just visible, however also touchable. It can directly mirror the developer’s creativity in the form of physical things, avoiding the disadvantage of “attracting to look good however not to make it look great”. As a result, prototype production is crucial in the process of brand-new product development and also product form analysis.

( 2 )Inspect the architectural design

Because the prototype is assembleable, it can with ease mirror the reasonableness of the structure and the ease of setup. It is convenient to discover as well as resolve issues early.

( 3 )Aviod the danger of straight make mold and mildews

Due to the fact that the expense of mold manufacturing is normally extremely high, reasonably large mold and mildews are worth hundreds of thousands and even millions. If unreasonable framework or various other problems are located in the process of opening up the mold and mildew, the loss can be pictured. Model production can prevent this loss and minimize the risk of mold and mildew opening.

The surface area of model:1, electroplate.2, anodized.3, painting.4, polish.5, lase.etc.

If you have a new item that require to make a prototype to design examination as well as examine the architectural design.Please do not wait to get in touch with us.As a prototype manufacturing facility for 20 years.We can make any kind of product by cnc machining.

5-axis CNC machining Service

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 5-axis CNC machining service

First we need to know what is the 5-axis CNC machining? 5-axis CNC machining is the use of computer numerical control (CNC) to move a tool or part simultaneously along five axes. The cutting tool moves continuously along each axis so that the tip is always perpendicular to the part. This process allows you to machine all kinds of complex parts.

Advantages of 5-axis CNC machining

Single Setup: 3-axis machines require multiple setups, which can lead to incorrect alignment, higher costs, and other errors. With 5-axis CNC machining, you can machine complex shapes in a single setup, increasing efficiency, saving time, reducing costs and preventing operator error.

Shorter tools: 5-axis CNC machining allows you to use shorter tools because you can lower the head and position the tool properly. This helps achieve higher cutting speeds without putting too much pressure on the tool. Shorter cutting tools also reduce tool vibration, which can cause cavities and cores. You’ll see a better surface finish due to less vibration on the 5-axis machine.

Complex Parts: 5-axis CNC machining process allows you to machine complex parts that would otherwise require casting. If you have a low-volume production or prototype, you’ll be able to machine the part in a few weeks, rather than waiting months for casting.

Increased tool life: You can maintain constant chip load and optimal cutting position to improve tool cycle time and life.

Drilling: 5-axis CNC machining provides the ability to drill a series of holes with various compound angles in time. This saves a lot of time – if you are using a 3-axis machine, you will need to use different settings for each face.

Collision avoidance: the ability to tilt the table or cutting tool to prevent collision with the tool holder

Here’s the advantages of 5-axis CNC machining.

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How To Choose The Steel Material Of Mold For Plastic Parts

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How To Choose The Steel Material Of Mold For Plastic Parts
The selection of the forming parts materials
The forming parts is the mould parts that contact directly with the plastic parts to make them formed,such as cavity, mold core, sliding block, insert, inclined top, side pull ans so on.
The material of the forming parts is directly related to the quality and life of the mold,it also will affect the appearance and the quality of plastic product.That is why we need to attach important to the selection of mold material and choose it according to the requirement of mold and the feature of plastic product.
The selection principle of forming parts material is based on the type of plastic,the shape of the product,the dimensional tolerance of the product,the appeance quality of the product and the requirement of use.At the sametime,we also need to take into account the material’s cutting,polishing,welding,etching,deformation,wear resistance and other properties,meanwhile,considering the economy and mold manufacturing conditions and processing methods.
1.About cavity and mold core of the mold for the clear plastic product,we can use the high grade imported steel with high mirror polishing performance,such as 718 mold steel,NAK80 mold steel,S316 mold steel,H13 mold steel,etc.
2.About the mold for the plastic product that require very nice cosmetic apperance and mass production,the cavity can be made with the imported slap-up steel with high mirror polish,such as 718 mold steel,NAK 80 mold steel,etc.The mold core can be made with Medium and low grade imported P20 mold steel or P20+Ni mold steel,such as 618 mold steel,738 mold steel,638 mold steel and 318 mold steel.For the production vlume is not large,we also can use S50C mold steel,S55C mold steel,etc.
3.About the mold for the plastic parts that didn’t require very nice cosmetic surface,the cavity and mold core can be made with mid-range imported P20 mold steel or P20+Ni steel.
4.About the mold for the mechanical parts that do not have any special requirement for the product’s appearance,we can use low-end P20 or P20+Ni steel material to make the mold with medium and large size and use the high quality carbon steel to make the mold core.
5.About the plastic product that contains corrosive elements such as fluorine and chlorine or the plastic product that require flame retardant,the mold can be made with corrosion-resisting steel.
6.About the mold will have strong friction and impact on steel when forming,such as the mold for injection nylon+glass fiber material. We can make it with H13 class steel that have the advantages of high wear resistance, high thermal tensile strength and high toughness.
We can use CNC machining,3D printing,vacuum casting and injection molding process for the plastic product,and we will use the mold according to the feature of the plastic prodcut require.If you have plastic parts need to make prototype,small batch or mass,please contact us for suggestion and quote.

custom vacuum casting

How does the prototype manufacturer process the surface?

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  1. Manual grinding and polishing

This method does not require special equipment, and its adaptability is relatively strong, mainly depends on the experience and technical level of the worker, and the efficiency is low (about 1/3 of the entire prototype model cycle).

  1. Digital prototype polishing machine

This polishing tool adopts digital control, digital display and control of process parameters, and is equipped with a complete set of grinding heads and abrasives for semi-automatic polishing. It has the advantages of small size, convenient use, stable quality and good repeatability. Application scope: a. Material: various prototype materials, including cast steel, forged steel, aluminum alloy and zinc alloy. b. The surface size of the prototype: 100×100 (mm)-1,500×3,000 (mm).

  1. Ultrasonic hand polishing machine

It can complete the polishing of narrow grooves, slits, edges, corners, etc., which are difficult for ordinary polishing tools (electric grinding soft shafts, etc.) to penetrate. The edges and corners will not collapse after polishing, and the accuracy of the prototype model will not be affected. Using this tool for polishing can quickly reshape and polish rough surfaces without being limited by the shape of the workpiece and the hardness of the material, and has no requirement on the original surface roughness, and the efficiency is relatively high.

The E-make team has more than 30 years of combined experience in prototype machining, CNC manufacturing（metal, plastic parts machining）, vacuum casting service and 3D printing service. And The E-make company has been providing high quality rapid prototype manufacturing services for major enterprises.

Please feel free to contact us. If there is anything we can do for you！

sheet metal stamping working

Sheet Metal Fabrication

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Sheet Metal Fabrication
Machining metal sheet material also called as metal plate fabrication,which mainly include cutting,bending,brake forming,stamping,welding,riveting and so on.Regarding sheet metal,we probably can understand that is a parts of constant thickness during processing.
Sheet metal is widely used in mechanical manufacturing,for example,we usuallly will use metal plate for making chimney,metal bucket,ventilation shaft,oiler,etc.
About the material,sheemt metal fabrication generally will use such as SPCC,SHCC,SECC,SGCC,copper,brass,red copper,beryllium copper,stainless steel (mirro surface,brush surface,matte,etc),aluminum (6061,6063,hard aluminum,etc).The manufacturer will offer their suggestion according to the use of the product,the cost that customer require.
1.SPCC mainly be used in electroplated parts and coated parts.The thickness of SPCC sheet parts is thinner than 3.2mm,with low cost and easily formed.
2.Like SPCC material,SHCC material mainly be used in electroplated parts and coated parts,with low cost.But the thickness of them are thicker than 3.0mm,also,they are hard to be formed.Mostly will be used for flat components.
3.SECC and SGCC material mostly for the parts that do not require surface treatment.Also,the cost for make them are highly.
4.Copper mostly for the product that require conduction of electricity,which will takes high cost.The surface finish for copper generally is nickel plating,chrome plating or without surface finished.
5.The surface treatment we usually will use for aluminum alloy material is anodizing,silver plating,nickel plating.
6.The section aluminum material with complex structure mostly will be used in subrack.
7.The stainless steel material made parts generally without surface finish.
The ways to cut material in metal plate machining as following.
1.The shears mostly is for cutting the simple shape material,tolerance is lower than 0.2mm,which are with low cost,but only can be used in machining the sheared strip or lump material.
2.The puncher can cutting the material into kinds of shape,the advantage of making sheet metal by puncher is with short time production,high efficiency,high tolerance and low cost,which are suitable for bulk prodcution,but it will need to make mould before producing.
3.About cutting the material by NC,we will need to programm before machining.The feature of this machining way is with low cost and tolerance is 0.15mm,but the structure of parts will be effcted by the structure of the tool.
4.We also can use laser cutting process to cut the material out of shape.Like the way of NC,laser cutting also need to programm before working,This way can cut the flat piece with complex shape,and tolerance is 0.1mm,but the cost of this way is high.
5.The saw machine can be usd in such as section aluminum,square tube, diagram tube and round bar material,also with low cost and low tolerance.

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Analysis of the five elements that need to be met in injection molding

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Plastic molding is the process of making various forms (powders, pellets, solutions and dispersion) of plastics into products or blanks in the desired shape.The manufacturing process of most cosmetic packaging materials is mainly through the four key processes of mold molding, surface treatment,printing,and assembly.The molding process is an indispensable key part.Injection molding is a method of producing shapes for industrial products.Products usually use rubber injection molding and plastic injection molding.Injection molding can also be divided into injection molding compression method and die-casting method.Injection molding machine is the main molding equipment that uses plastic molding molds to make plastic products of various shapes. Injection molding is realized by injection molding machines and molds.

The five elements that need to be met in injection molding are:

  1. Temperature:Temperature is the first step of injection molding.Temperature can be divided into:drying temperature,material temperature,mold temperature, these are some of the most important factors.The drying temperature is to dry the polymer in advance in order to ensure the quality of the molding,to ensure that the dry and wet of the polymer are within a certain amount;The material temperature is to ensure that the polymer is plasticized normally,and the mold is filled and formed smoothly;
  2. Speed:Speed is divided into:injection speed,Melting speed,loosening and retreating speed,opening and closing mold speed,thimble forward and backward speed.The increase of the injection speed will affect the increase of the filling pressure,and the increase of the injection speed can increase the flow length,and the product quality can be uniform to ensure the quality of the product.High-speed injection is suitable for long-process products,and the size of the product is controlled at low speed;Melting speed affects plasticizing ability,plastic mold processing is an important parameter of plasticizing quality,the higher the speed,the higher the melt temperature,the stronger the plasticizing ability;
  3. Pressure:Pressure is divided into: injection pressure,holding pressure, back pressure,clamping pressure,mold protection pressure,ejection pressure.
  4. Position:The position can be divided into:mold opening position, ejection retreat stroke,metering stroke,leg loosening amount,injection stroke,and buffering amount.The mold opening position is to ensure the normal operation of the demolding parts.The effect of the ejection back stroke on the partial spring return to the ejection limit protection.The metering stroke is to ensure that there is enough plastic to fill the mold to ensure product quality.
  5. Time:The time is divided into:cooling time,sol time,drying time, cooling time,melting time,drying time,cycle,injection time,and pressure holding time.The molding of plastic shell paintingproducts requires a certain period of time.The holding time is to prevent the melt back flow and cooling shrinkage.The cooling time ensures that the product is solidified and prevents deformation;the melting time is to ensure that the glue is fully melted;the drying time is to ensure that the product does not become elongated or defective.

The E-make company has 30 years of experience in custom-made production of injection molding.The plastic injection molding products will be exquisite in appearance,reliable in quality and delivered on time.If you want to customize the high-precision injection molding products.All information from customers was kept secret,we can sign NDA with you before starting any work.If you need any help,please feel free to contact us.

sheet metal fabrication

Sheet Metal Working

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Sheet Metal Working
With the characteristics of light weight, high strength, conductivity, low cost and good mass production performance,metal plate is a technology that has been widely used in electronic and electrical appliances, communication, automobile industry, medical devices and other fields. For example,it is an essential part in computer chassis, mobile phone,and so on.
The material of metal plate widely be used in electronic enterprises is SPCC,SECC,SGCC,SUS301,SUS304,etc.There are three main types of sheet metal processing: blanking, bending and stretching. Different processing technologies have different requirements for sheet metal. The selection of sheet metal also need be considered according to the shape of the product and processing technology.The following is the impact of materials on sheet metal processing technology.
a,The influence of materials on punching process.
Punching requires that the plate material should have enough plasticity to ensure the plate will not crack during machining.The soft materials such as pure aluminum,antirust aluminum, brass, red copper and mild steel have good punching performance,which can be blanked to the parts that have a smooth section and a small inclination.The quality of the hard materials is not good after punching,such as high-carbon steel,stainless steel,duralumin and ultralumin, the section unevenness is large, especially for the thick plate material.
b,, The influence of materials on bending process.
The plate materials to be bent should have sufficient plasticity and low yield limit.The plate with high plasticity is not easy to crack when bending. The plate with low yield limit and low elastic modulus has small rebound deformation after bending, and it is easy to obtain the bending shape with accurate size. Materials with good plasticity such as low carbon steel, brass and aluminum with carbon content less than 0.2% are easy to bend and form; Materials with high brittleness, such as phosphor bronze (qsn6.5 ~ 2.5), spring steel (65Mn), hard aluminum, superhard aluminum, etc., must have a large relative bending radius (R / T) during bending, otherwise they are easy to crack during bending.
c,The influence of materials on tensile process.
Sheet metal stretching, especially deep stretching, is a difficult kind of sheet metal processing technology. It not only requires the stretching depth to be as small as possible, the shape to be as simple and smooth as possible, but also requires the material to have good plasticity. Otherwise, it is very easy to cause overall distortion, local wrinkling and even tensile cracking of the parts.

CNC turning machining Service

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CNC turning is one of the most basic and most commonly used cutting processing methods.For most work pieces with revolving surfaces,it can be processed by CNC turning machine,such as inner and outer cylindrical surfaces,inner and outer tapered surfaces,end surfaces, grooves,threads,and rotary forming surfaces, etc. .
With the development of modern technology,there are more and more high-strength and high-hardness engineering materials.Traditional CNC turning machine has been unable to meet or realize the processing requirements of certain high-strength and high-hardness materials, while modern hard cnc turning technology can Make it possible and obtain significant benefits in production.The following is a brief introduction to the characteristics of CNC turning machining:
(1)CNC turning machining efficiency is high:
CNC turning uses large cutting depth and high work piece speed,and its removal rate is usually several times that of CNC grinding.CNC lathes can complete various surface machining in one clamping process,while grinding requires multiple installations,so the auxiliary time of CNC turning machining is shorter,and the position accuracy of each processing surface will be higher.
(2)The cost of equipment investment is low.Under the same productivity, the investment of a lathe machine is obviously better than that of a grinder,and the cost of its auxiliary system is also low.In the production of small batches of parts, CNC turning does not require special equipment, and the processing of large quantities of high-precision parts requires high rigidity, positioning accuracy, and repeat positioning accuracy for CNC machine tools.
(3)The lathe suitable for small batch flexible production is a flexible processing method with a wide range of processing.The lathe is easy to operate and the turning fixture is fast.Compared with grinding,hard turning is more suitable for the requirements of flexible production.
(4)Hard CNC turning can obtain better overall machining accuracy.
(5)CNC turning machining surface quality is excellent,processing roundness is accurate,and can ensure high position accuracy on the processing surface,Also will not produce burns and cracks during the cutting process,and most of the heat generated during the processing of the parts will be taken away by the cutting oil.
From the perspective of processing technology and programming, five-axis CNC machine tools have the following advantages in the processing of complex inclined surfaces:
1.Improve processing quality and improve efficiency.
2.Expand the processing technology category.
3.To achieve a new direction of compound development trend.
The E-make team has more than 30 years of combined experience in prototype machining,CNC manufacturing.And has a high-level technological group of 25 peoples.The processing quality of the rapid manufacturing is stable,the processing precision is high,and the appearance is exquisite.If you need any help,please feel free to contact us.

Cnc Machining Acrylic Parts

Acrylic Rapid Prototpying

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Acrylic Rapid Prototpying
We usually will use acrylic or PC as material to make prototypes if we need the parts be transparent or semi-transparent.If we have high requirement about the transparency of the product,acrylic is a great choice.
Acrylic,we also call it as PMMA,which is a organic glass.Below is some information about acrylic made prototype.
1.The way of acrylic parts machining.
For quantity production,we usually use injection molding process to produce acrylic product.For prototype production,we prefer to make the acrylic parts by CNC milling,CNC turning or vacuum casting proess,which process is more suitable to use is up to the feature that the product require,such as the strength and structure.For example,the strength of the parts is better if make by CNC machining technology.But for small brach production,vacuum casting (urethane casting) is a nice option.
2.The advantage of acrylic prototype.
Acrylic material have nice transparency,so the acrylic made prototype can be crystal clear after polish.PC prototype also can be polish to clear,but the transparency is not good as acrylic.
3.The disvantage of acrylic protoype
Acrylic material is friable and have poor toughness because of its physical property.Therefor,we need to be very careful as it is is prone to damage during machining.
4.The surface treatment of acrylic prototype.
For some mechanical parts,if we didn’t have special requirement of the surface finish for the acrylic parts,we don’t need to do any surface finish,just the tooling surface is fine.If we need a smooth surface for the parts,we will grind or milled sand the parts.If we need a frosted surface,we will get it by sandblasting.If we need a crystal clear surface,we will need to sand the parts,and then polish them,which will takes many time,so this surface effect is more expensive to get.If we need the acrylic product has mirro surface and with colors,such as shiny rose gold or silver,we will make them by electroplating.This surface looks really great,but will need the parts have very nice smooth surface before plating.So we will need to polish the parts before plating work.
5.The application of the acrylic prototype.
Mostly,we will use the acrylic made parts as cosmetic parts,which means we will require high requirement for the surface finish.Of course,the surface might not so important if just a mechanical parts.
Our factory are professional in making acrylic product in many years,our team have enough experience can help in acrylic product deverlopemnt and production.If you have any project need to make prototypes or production,we are glad to receive your inquiry.

Application of ABS material in 3D printing

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ABS is one of the main materials for 3D printing.The reason why it can become a consumable for 3D printing is determined by its characteristics. ABS materials have heat resistance,impact resistance,low temperature resistance,chemical resistance and excellent electrical properties，Product dimension stability and other characteristics.

At present,ABS is the most stable material among 3D printing materials. It has good hot melt and impact strength,and it is also the preferred engineering plastic for fused deposition molding 3D printing process.For now,ABS is mainly pre-made into silk and powdered.The application range of ABS materials covers almost all daily necessities,engineering supplies and some mechanical supplies,and has a wide range of applications in automobiles,home appliances,consumer electronics and other fields.

Printing performance:

  1. ABS materialis quite easy to print.No matter what kind of extruder is used,the material will be extruded smoothly without worrying about clogging or solidification.However,the steps of ABS material after the extruder are a bit difficult.ABS material has the characteristic of shrinking when exposed to cold,and will partially fall off the heating plate and hang in the air,then it will be causing problems.In addition,if the height of the products that needs 3D printing is very high,the ABS material sometimes peels off the entire layer during the 3d printing process.Therefore,the heating plate cannot be omitted when ABS material is used for 3d printing.
  2. ABS material is relatively flexible,so it is suitable for making wearable products.

Strength:As long as 3D printing is carried out at an appropriate temperature and the layers of materials are firmly adhered,the strength of ABS will become quite high.But the ABS material is also flexible after 3D printing,even if it is under pressure,it will only bend and not break.

Odor: The biggest disadvantage of ABS material is that it produces a strong odor during 3d printing.Regardless of the material,it is recommended that you perform 3D printing in a well-ventilated room. This is especially true when using ABS materials.

ABS-M30 is a production-grade plastic that is specially designed for 3D printing with FDM technology.This strong and common material helps to test and repeat the work more frequently,Ultimately reduce risks and create better products,speeding up the time to market.

Due to performance reasons and the price is more suitable,3d printing ABS material it is very suitable for conceptual models and parts with medium requirements, including functional prototypes.The colors of ABS material are natural color,white,black,dark gray,red and blue.In addition,the color can be customized when 3d printing.

The E-make company is a rapid prototyping manufacturer.

Our factory provides high quantity 3D printing、Vacuum casting service、CNC machining service and injection molding service.

All information from customers was kept secret,we can sign NDA with customer before starting any work.

If you need any help,please feel free to contact us!