Como você lida com pedidos de usinagem CNC complexos ou personalizados?

As a machinist, I often rely on the detailed specifications and requirements provided by clients for complex CNC machining orders. While I might not always know all the technicalities, it's crucial for toolmakers to have this information. This includes understanding tolerances, knowing particular cutting edges, and finishes. Knowing which part of the tool will be used for cutting and the desired finishes helps immensely in manufacturing the tool effectively. If I receive clear and comprehensive details, it allows me to verify the feasibility of the design with our CNC machines and software, ensuring a smoother process and better end results.

From a manufacturer's point of view, when there is an order, the sales and their team have already done much for the custom machining order. They should have completely understood the client's demands and the part drawing's specifications. That means the sales and their team should be professional and quick-responded before the order. For anything you are not sure about, don't guess it or decide anything privately FOR the clients. It's worth time to understand it well by learning and discussing it with your team. Once you fail to get the right answer by yourself, be brave to check with the client. Trust me, understanding some points even by learning from your client is also a kind of professionalism.

A good contract review process is the key to checking that you understand the customer requirement, and where possible make best use of your internal team to check that everyone is on board and understands what is potentially coming at them, so that they can raise any concerns early, allowing involvement with the customer at the start of a quote/bid process or at commencement of planning the method and approach to produce the work.

I once worked on a high-precision aerospace component requiring tolerances of ±0.005 mm and made from titanium, which is challenging to machine. Here is what we did: 1. After reviewing the CAD models, I noticed the design included an undercut that required either design changes or the use of the rotary table. 2. I reached out to the client and explained the limitations. Together, we decided to slightly modify the design, making it more machinable while controlling costs. 3. I also recommended switching to a more machinable titanium alloy to reduce tool wear and improve production speed. 4. After agreeing on the changes, we finalized the specifications and moved forward with production.

Handling complex or custom CNC machining orders requires a combination of detailed planning, precise execution, and clear communication. Initially, we collaborate closely with clients to fully understand their specifications and requirements. Utilizing advanced CAD/CAM software, we create detailed models and simulations to anticipate potential challenges. Our experienced machinists then select the appropriate materials and tools, ensuring optimal machine settings for precision and efficiency. Throughout the process, we maintain strict quality control measures and provide regular updates to the client, ensuring that the final product meets or exceeds their expectations.

It's not enough if only the sales and the quoting team understand the custom machining order well. Instead, every person involved in this project should completely understand what they should do in their posts and links. For example: 1. Plan a workflow like when to purchase the right raw material; Which machining equipment is suitable for this complex part? What machining inserts, drill bits and taps should be prepared? Are there any jigs or fixtures needed?... 2. Quality control during the manufacturing: First Inspection, Random Inspection, when(after a number of parts were completed) the tool must be replaced to guarantee the quality; Should the surface should be carefully protected by some special packing, etc.

Plan, plan, plan, and make sure everyone in the team buys in to the plan. Consider all aspects of the requirement, and very importantly check that the resulting solution meets not only the technical specification required but also the commercial aspects - you have to make money doing the work or your business will fail in the long run.

Instead of just focusing on the best cutting tools for the material, think ahead about tool life and maintenance. Using higher-grade tools may come with a higher upfront cost but could extend tool life, reduce downtime, and increase overall efficiency. Setting up a tool maintenance schedule—especially for multi-part production runs—ensures that you avoid unexpected wear or breakage during critical moments. Also, Integrating tool probing systems into the setup can automatically measure tool length, wear, and offsets, improving accuracy and reducing setup time. This ensures you have precise data on your tools during the production phase, reducing errors and allowing for better quality control in complex jobs.

Design Analysis: Review designs, assess challenges, & choose materials. Workflow Planning: Create a detailed production plan, optimize setups, reduce production time. Quality Control: Set clear standards for dimensions & surface finish. In-Process Inspection: Regularly inspect parts during machining, document results, & make adjustments. Documentation: Maintain records of processes, ensuring traceability. Continuous Improvement: Encourage a culture of learning & apply lessons to refine workflows. Team Training: Keep the team well-trained in CNC machining techniques. Final Inspection: Conduct a complete final inspection to ensure compliance w/ specifications.

I start by looking at the end result and braking it down into a series of small and achievable operations. Especially on a machine without a 4th axis, I have to be intentional about the order of operations, and making sure that the sequence is right to enable a successful end result. If I need to flip a workpieces to machine two sides, I need to think about positioning and indexing, my setup and work holding, as well as the tool path ordering.

Don't forget to indicate all the specific requirements of the post-processing and finishing. Not only indicate that by talking online with the surface finish plant but also indicate that with a label in your part lots to avoid any quality issue caused by information missing in some links. There should be a professional person to follow the post-processing and finishing carefully.

This can make or break the project. No matter how great you have produced the work, if your subcontractors handling any final finishing let you down its you that look bad in the eyes of the customer. So make sure you share the detail of the requirement with these subcontractors early, and keep them informed of when they will receive the work and when you need them back. If there are going to be delays that effect the end customer communicate that with them early, they may be planning their own build program around the dates promised and slippage from you (even if caused by the subcontractor) can be expensive and damaging to the customer. Consider packaging to and from the subcontractor, damage at this stage is the last thing you want!

With custom orders, we never proceed with production until we get an approval or verification from our customer on the drawings they send or we send them. Having a great cad drawing will almost eliminate chances of mistakes. Second is to also let the customer know that extremely custom routes and cuts could take longer than standard ones, this should be communicated before the customer even puts an order in. When the product leaves the facility, you should seek feedback from the customer then you can add this to your list of programs for potential customers and or the same customer who ordered for future businesses.

Customers like to receive progress reports and updates during manufacture. At various simple 'gates' drop the customer an email telling them things that give confidence that you are progressing their order on track to the original plan. Simple things like "Programming is complete on your work", and "Material has arrived, due to be on the first machine on Tuesday". Even better to send photos at the machine or between operations, pictures reassure the client that things are going well and that you are thinking about them. After completion and delivery always follow-up. Don't assume that just because you haven't heard from them that means everything was exactly as they hoped. It helps when it comes to getting paid and to get repeat orders.

We do a fair amount of prototype and new product work, often highly complex due to design or materials. Incredibly thorough planning is a necessity. Our best results come when we involve our internal programming, quality, material managers along with our floor leads from each department. Externally we will bring in our tooling and workholding resources. Then after planning, reach back out to the customer with any concerns we see, discuss any difficult features and possibly ask to open up some tolerances on certain features etc. Our ERP system, Proshop, also has several detailed preprocessing checklists we can work through to make sure we don’t miss anything.

If the degree of complexity looks challenging, be honest with the customer at the start. They may be able to compromise a certain aspect but then other things might be non-negotiatable, so best they know at the start if they may not get exactly what they have drawn or modelled. Keeping the customer aware of the "art of the possible" is always the best plan, avoiding disappointment at the end, just before when you want to get paid!