If you need complex parts that can only be manufactured by CNC milling, it’s important to find the right machine shop to do the job. Before you can select a reliable and competent company with confidence, however, you must know what to look for in a machine shop. Otherwise, there’s no way to be sure your project will be in the right hands. 

Here are some of the most important considerations to keep in mind:

1. Experience and Expertise

• Years in the Industry: Choosing a machine shop with a proven track record and substantial experience is vital. Look for a company that has been operating for several years and has successfully completed projects similar to yours.
• Specialization: Determine if the shop specializes in CNC milling services. Expertise in this particular area ensures that they have the necessary skills, knowledge, and equipment to deliver high-quality results.

2. Advanced Technology and Equipment

• State-of-the-Art Machinery: Check if the CNC machine shop utilizes modern, well-maintained equipment. Advanced machinery increases efficiency, accuracy, and the ability to handle complex projects effectively.
• Diverse Capabilities: A reputable CNC machine shop should have a wide range of machining capabilities, including 3-axis, 4-axis, and 5-axis CNC milling. This ensures they can accommodate various project requirements.

3. Quality Control and Certification

• ISO Certification: Look for a CNC machine shop that is ISO 9001 certified. This certification guarantees that the company follows strict quality control processes and maintains high standards.
• Inspection and Testing: Ensure that the shop has robust quality control measures in place. This includes thorough inspection and testing procedures to verify the accuracy and precision of the machined parts.

4. Material Selection and Sourcing

• Material Expertise: Different materials require specific machining techniques. A reliable CNC machine shop should have expertise in working with a wide range of materials, including metals, plastics, composites, and more.
• Material Sourcing: Inquire about their material sourcing capabilities. A reputable shop will have established relationships with trusted suppliers to ensure the availability and quality of materials for your projects.

5. Customization and Flexibility

• Customization Options: Discuss your project requirements with the CNC machine shop and ensure they can accommodate any customization needs. The ability to adapt and tailor their processes to your unique specifications is crucial.
• Quick Turnaround Time: Timeliness is essential in today’s fast-paced manufacturing industry. Choose a CNC machine shop that can deliver projects within your desired time frame without compromising quality.

6. Customer Reviews and References

• Online Reviews: Research online to read customer reviews and ratings about the CNC machine shop. Pay attention to feedback regarding their professionalism, communication, adherence to deadlines, and overall satisfaction.
• Request References: Don’t hesitate to ask the CNC machine shop for references from their past clients. Contact these references to gain insights into their experience working with the shop

Selecting the right CNC machine shop is a critical decision that directly impacts the success of your manufacturing projects. By considering factors such as experience, advanced technology, quality control, material selection, customization options, and customer reviews, you can make an informed choice. Remember, finding a reliable CNC machine shop that aligns with your requirements will ensure top-notch CNC milling results and a fruitful collaboration.

About APM

Advanced Precision Machining provides a wide range of CNC milling services. Founded in 2005, we have earned our reputation as the leading machine shop in Colorado because of our cutting-edge technology, meticulous attention to detail, and exceptional customer service. To discuss your manufacturing needs, reach out today.

Computer numerical control (CNC) milling uses software-guided machinery to create precise parts, many of which have intricate or complex features. Because this process is so accurate, it can be used to produce parts that are needed for high-stakes applications. In the medical field, for example, CNC milling is used to create customized medical devices, prosthetics, and surgical instruments. 

This technology has revolutionized the healthcare industry by providing a more efficient way to yield even the most complicated devices. It also reduces production time and increases patient satisfaction.

Because they’re so versatile, CNC milling services are in high demand. The industry was worth over $14.6 billion in the United States in 2018 and is expected to reach almost 23 billion in 2026. A significant portion of this increase will undoubtedly be attributed to its applications in the medical field. 

Let’s take a look at some of the most common medical parts that are produced by CNC milling:

Custom Implants

CNC milling can create implants that are specifically designed to fit the patient’s unique anatomy. Such implants are preferable to the standard “one-size-fits-all” devices, since even a small deviation from average can hinder healing and cause ongoing issues like chronic pain.

Custom implants are most often used to address medical conditions like bone cancer and severe arthritis. Because they yield better patient outcomes and cause fewer complications, though, they’re gradually becoming the norm in all kinds of other scenarios.

Dental Restorations

Since it’s such a precise technology, CNC milling can be used to create dental restorations such as crowns, bridges, and veneers. With the help of specialized software, this process ensures that every restoration is made with the highest level of accuracy, resulting in a perfect fit for the patient. It’s primarily used to produce dental restorations made from ceramic, metal, or composite resin.

Prosthetics

Patients who have lost their limbs to injury or illness can get incredible prosthetics thanks to CNC milling. To enable the creation of prosthetics, body scans are digitized and then used to build an identical 3D model on a software platform. The model is then used in the creation of the blueprint for the replacement limb.
Prosthetics were traditionally created manually, which left considerable room for error. With CNC milling technology, though, prosthetics can be made with the highest level of accuracy, resulting in a perfect fit and better quality of life for the patient.

Surgical Instruments

Scalpels, forceps, and other tools used in surgical procedures are now made with CNC milling. These machines can produce instruments with intricate details and features that are difficult to achieve via traditional manufacturing methods. As an added benefit, these computer-automated machines have no quantity restrictions. That means they can meet the demand for both low-volume individualized surgical instruments and massive numbers of identical precision components.

Let Us Produce Your Custom Medical Devices

CNC milling technology has significantly improved the medical industry by enabling the creation of complex, precise, and customized medical devices such as implants, prosthetics, dental restorations, and surgical instruments.
At Advanced Precision Machining, we specialize in custom CNC milling and take pride in delivering the highest quality products to our clients in the medical industry. Our state-of-the-art equipment and experienced team are dedicated to providing superior service, precision, and quality. Take your medical device innovation to the next level with our CNC milling services.

In our tireless and dedicated effort to manufacture high-quality precision parts, and maintain a reputation for accuracy and on-time reliability, Advanced Precision Machining (APM) Colorado machine shop relies on an assortment of Computer Numerical Control (CNC) machines in our facility. In today’s modern machine shop, CNC equipment typically consists of multi-axis milling machines, lathes, routers and grinders, but also newer technology such as robotic welders, laser marking machines, and 3D printers. With origins dating back to the 1950s, what was known first simply as “numerical control” lessened the need for constant operator attention and took the machine tools out of the hand of machinists, allowing for a first of its kind automation. Today, the punch tapes associated with numerical control have given rise to advanced computing technology, programming languages and computer-aided design (CAD) capabilities, making CNC technology an integral part of most manufacturing processes.

At its core, CNC involves the use of computers to control the various machine tools listed in the first paragraph, and they function through the use of numerically controlled computer programs, most often written in a CNC machining programming language called G-Code. G-code sends the signals, or directions, to a piece of machining equipment on the shop floor directing such essential functions as cutting tool speeds, spindle position, feed rates, and all other coordinated movements. Most modern CNC systems have become highly automated and quite complex, augmented by the addition of CAD and computer-aided manufacturing (CAM) programs. Due to the complexities involved with modern machining, CNC machinists have evolved to become skilled in all aspects of drawing and design, code writing, and equipment operation. When all’s said and done however, a precision machined part in the end is only going to be manufactured as well as the programming that was input to create it. Because of its importance, APM would like to provide a short primer on some common CNC programming methods.

As stated, CNC milling machines require a set of precise programming instructions to control nearly every aspect of the milling and machining process. After a CAD drawing is first drafted, the actual programming code (G-code) is created in a language that the CNC machine will understand. The program is then loaded into the microcomputer, or controller unit directly on the machine where it is stored in memory, then tested for accuracy. A CNC machinist next loads the required tools and material, then the computer directs the machine to perform the cutting operations according to the programmed instructions. Given the critical nature of CNC programming, let’s briefly examine three of the most commonly used methods: manual, conversational and CAM programming. 

1.  Manual (non-conversational) CNC Programming

Perhaps thought of as the purest method, manual programming involves a CNC machinist preparing G-code commands without the assistance of a computer, thereby manually giving the CNC machine instructions on where to move, how fast, and on what path. Also known as non-conversational, it allows for complete control over a part program. This intimacy between programmer and machine brings out better machine performance when compared to more automated computerized methods. Because it’s done by hand, manual programming teaches strong discipline and is ideal for simple or high-volume work, although it’s time consuming and runs the risk of human error.

2. Conversational (shop floor) CNC Programming

Conversational, or shop floor programming involves creating a set of programming instructions directly at the CNC machine using displays and menu-driven functions. The need to manually create G-code is either hidden or bypassed entirely, allowing a CNC machinist to step up to a machine and generate a CNC program quickly and easily. The program takes over and puts the machine in motion according to the commands given. It’s easy to learn and simple to use for small lots and short cycle times, but limited to more basic machine parts without complex tool paths.

3.  Computer-aided Manufacturing (CAM system) CNC Programming

A computer-aided manufacturing system combines elements of both manual and conversational CNC programming by computer generating the G-code written in manual programming, then directly and automatically transferring it to the machine tool. The dimensions specific to a workpiece’s design are imported from a CAD system, the machinist directs the machining commands through a menu, the G-code program is generated, loaded into the machine, then it is left to run. Although it automates many processes and improves output, the total machine control associated with manual programming is limited. 

The description and methods shown for developing the CNC programs all have developed their own specific niche in the precision machining industry. They of course have a comprehensive list of additional pros and cons surrounding their use, and as any CNC machinist can tell you, their preferred use comes down not only to specific machining needs, but also personal preference. Be sure your machine shop chooses the optimal CNC programming method to deliver your parts accurately, on time and on-budget.

Need help with your next project requiring the precision and accuracy delivered by CNC, or want to learn more about the range of precision milling and machining options available to you, then contact our Colorado CNC machine shop. Advanced Precision Machining’s reputation for quality parts, on-time reliability and exceptional customer service cannot be matched! We’re happy to discuss any machining needs you have. Feel free to give us a call at 303.776.1910

For more APM machine shop information; Like us on Facebook, follow us on Twitter @APMLongmont, or connect with us on LinkedIn.

About the Author

Gerry Dillon is a co-founder, current owner and certified CNC machinist at Advanced Precision Machining (APM), a full-service machine shop located in Longmont, Colorado. Before making his home in the United States in 2000, Gerry was born and raised in Ireland and took an interest in milling and machining from an early age, ranking #1 in the Irish National Apprenticeship Program. In 2005, he began what’s grown into a leading Colorado machine shop. Gerry brings over 30 years of machining experience to the shop floor, and is certified in all aspects of geometric dimensioning and tolerancing.

To an outsider unfamiliar with CNC machine shop operations, once the chips stop flying, the milling machine winds down and another precision machine part rolls out, they may well think the end product is accurate and up to specification. Unfortunately, this is not always the case. At Advanced Precision Machining, and any CNC shop for that matter, no finished part is delivered to a customer until it passes an inspection reporting process. A part’s dimensions must conform to the tolerances set in place for its design, and this includes thoroughly inspecting the finishes of all machined surfaces. As is often the case, a part may meet specific dimensional specifications, but must be scrapped because its overall appearance and surface finish is not up to standards. This not only results in an aesthetic issue, but more importantly, can negatively impact a part’s functionality.

The bottom line is that during the finishing stages of the milling and machining process, having to send parts to the scrap bin is less than a desirable outcome. CNC machinists by nature are detail-oriented, take great pride in their work and want to see a project through to completion. Scrapping parts as a result of surface finish issues can also be a real profit killer for machine shops. Poor quality leads to increased costs, more downtime, delayed deliveries, and in the worst case scenario, lost orders. The question becomes; how do machinists and shops address this issue? What can be done when the end results aren’t up to par? Let’s take a quick look at just a few simple tips and tricks on how to get the best surface finish possible using a CNC milling machine. Bear in mind that this is only the tip of the iceberg! 

1. Increasing cutting tool speed

Faster velocities, measured in surface feet per minute (SFM) mean material is in contact with the cutting tool for less time. This works to reduce edge buildup resulting in poor surface finishes, and also extends the life of the cutting tool. Tool failure is a leading cause of damage to a precision machined part. Never estimate or guess at the required speeds for your job. 

2. Always clear away/control chips

Clearing excess chips, or built up edge (BUE), and not allowing them to contact the workpiece during machining operations is a vital task and key to producing a high-quality surface finish. Chips and BUE have a tendency to build up, and if not cleared, can easily damage surface finishes as the cutting tool makes contact with them. Chip breakers, compressed air, and the best solution, flood coolant can be used to clear away chips and BUE for better control and less scratching/damage to parts.

3. Different tools should be used for roughing vs. finishing applications

Don’t finish a part with the same tool used for roughing. Instead, slightly used roughing tools should be utilized for the bulk of material removal, while brand new, sharper tools should be saved and only used for finishing passes. Tooling insert radius, rake angle, feed rates and insert material itself, when combined with roughing vs. finishing tools can lead to a higher quality finish.

To the layperson, simply examining a precision machined part for its aesthetic appearance may seem all that’s necessary once milling and machining has ended and delivery is near. Thoroughly inspecting completed work, regardless of material, is instead a critical factor for a part’s functionality; especially for applications in industries such as aerospace and medical device manufacturing. Excess chips and/or BUE, slow operating speeds, and improper tool use are leading causes of poor surface finishes. Lack of machine maintenance, low levels of cooling fluids, poor setups, and CNC programming errors are also contributing factors. The tips we’ve provided are applicable across a variety of machine shop operations, including milling, turning and grinding, and if adhered to, should go a long way to improving the surface finishes on your problem jobs, resulting in satisfied customers and repeat business.

Do you have questions? Want to learn more about surface finishing applications? APM’s Colorado machine shop is available for all of your inquiries. We’re dedicated to manufacturing the highest quality precision parts while providing the best customer service experience in the machine shop business. For additional information or to request a quote, please visit https://advancedprecisionmachine.com or call 303-776-1910.

For more APM machine shop information; Like us on Facebook, follow us on Twitter @APMLongmont, or connect with us on LinkedIn.

About the Author

Gerry Dillon is a co-founder, current owner and certified CNC machinist at Advanced Precision Machining (APM), a full-service machine shop located in Longmont, Colorado. Before making his home in the United States in 2000, Gerry was born and raised in Ireland and took an interest in milling and machining from an early age, ranking #1 in the Irish National Apprenticeship Program. In 2005, he began what’s grown into a leading Colorado machine shop. Gerry brings over 30 years of machining experience to the shop floor, and is certified in all aspects of geometric dimensioning and tolerancing.

With the holidays rapidly approaching, the ownership and entire team of professional CNC machinists at Advanced Precision Machining (APM) want to wish everyone seasons greetings and best wishes for a Happy New Year. We’d also like to thank our customers for their continued support and loyalty. The milling and machining business has remained productive for us, and the hard work of our employees has grown APM into one of the Front Range’s premier machine shop operations. Part of this work is dedicated to education and keeping our customers informed with regards to the many milling and machining techniques used in our sector of the precision manufacturing industry. So, as we reflect upon another successful year of operations and look forward to 2023, we want to take this opportunity to revisit what may appear on the surface to be a seemingly simple procedure we offer as part of our CNC turning services; the various methods utilized for generating screw threads. 

When looking at the simple threads on any screw, to the layperson, it might seem as if the machining techniques used in the manufacturing processes are among the least complicated on the machine shop floor. But in reality, due to generally higher cutting forces and tight tolerances, machining screws (aka thread turning), is significantly more challenging. When you factor in the additional demands required of micro-threading, utilized in products such as watches, eyeglasses, cell phones, and medical devices, you’ve upped the workload substantially. Herein lies the difficulties many shops face. From one-off specialty items, to mass-quantity production runs, more screw threads are produced in a given year than any other CNC machining element. 

While threading is used across many varying industries and takes on many roles, from the large scale down to almost micro levels for custom precision machining projects, every type of thread is ultimately machined to provide specific functions for specific applications. The processes involved in creating a screw thread are varied, encompassing a wide range of subtractive machining, deformative, transformative, and even additive methods. Today’s revolution in modern machine shop technology means precise and accurate screw threads can be produced more quickly, accurately, and efficiently regardless of size. What follows below is a brief look at the most common technique; the subtractive method of cutting screw threads.

Bearing in mind that thread turning involves both external and internal threads, with the latter being more demanding, choosing an appropriate application for machining screw threads is based upon the constraints of time, money, equipment, and the degree of precision needed. Subtractive CNC machining methods involve the removal of raw material from a blank, and are universally accepted as the most efficient, cost effective, and least complex methods to choose from. These include: Thread Cutting, Thread Grinding, and Thread Lapping techniques.

Thread Cutting (Tap and Die, Single Point, and Thread Milling Processes)

Tap and Die Method

• Metal screw threading using taps and dies goes back to the eighteenth century. A tap is designed to thread the inside, or female surface of a hole, such as a nut. This can be done manually using various tap wrenches, or power assisted with a CNC lathe or high speed milling machine. Dies form mates for tapped components by threading the outside, or male surface, of a metal cylinder such as a bolt. Again, this can be done with hand devices, or with CNC machining tools.

Single Point Threading Method

• Single-point threading is less common, and uses a single-point tool on a CNC lathe to impart a thread on the inside or outside of a rotating part. Single-point threading is favored over tap and die, or other methods, but only when certain manufacturing factors dictate it.

Thread Milling Method

• Thread milling is a more accurate CNC milling operation in which a rotating multi-point tool threads the surface of a workpiece if a helical toolpath can be maintained. It’s a useful alternative to standard methods for producing threads with good form, finish, and dimensional accuracy. Faster work, less breakage, and left or right-handed threads can be machined using the same tool.

Thread Grinding

The precision manufacturing of screw threads can also be performed on a variety of grinding machines utilizing specialized wheels accurately profiled to the desired thread pattern that traverse along the revolving workpiece. Thread grinding is typically used to produce threads to very exacting tolerances, or in extremely hard materials. The most common machine, the universal type, specializes in threading gages, screws, plugs, rings, hobs, and even other threading tools such as taps and dies.

Thread Lapping

• Lapping a screw thread involves a process of abrasion in which threads are finely finished on a workpiece by successively traversing, or lapping the workpiece as it revolves. Lapping helps achieve the highest precision and surface finish available, and is normally performed after thread grinding. Two surfaces are typically moved together via a machine with the abrasive material between them, producing the desired result.

Although the subtractive techniques involved in machining screw threads described above garner the most attention on the machine shop floor and are most commonly employed there, deformative or transformative methods, and even additive (3D printing techniques) warrant mentioning. Thread forming, for creating internal threads, and thread rolling, for creating external threads, both involve deforming or transforming the metal used to manufacture screw threads. In short, the threads are formed by pressing a shaped tool into a metal blank, commonly called a ‘thread rolling die’. Used in large production runs due to their efficiency, thread rolling/forming dies have the capability to produce one new piece per second and produce none of the waste, or swarf, that’s associated with subtractive methods. Additive manufacturing utilizing 3D printers is gaining increased potential for creating threaded parts, but the technology is not quite where it needs to be just yet. The good news is that further commercialization is on the horizon, and the industry is making some inroads into the dental implant and medical bone screw fields.

Need help with your next threading project, or want to learn more about the range of precision machining options available to you, then contact the CNC machine shop and thread generating experts at APM. Our reputation for quality parts, on-time reliability and exceptional customer service cannot be matched! We’re happy to discuss any machining needs you have. Call us at 303.776.1910 or send us an email.

For more APM machine shop information; Like us on Facebook, follow us on Twitter @APMLongmont, or connect with us on LinkedIn.

About the Author

Gerry Dillon is a co-founder, current owner and certified CNC machinist at Advanced Precision Machining (APM), a full-service machine shop located in Longmont, Colorado. Before making his home in the United States in 2000, Gerry was born and raised in Ireland and took an interest in milling and machining from an early age, ranking #1 in the Irish National Apprenticeship Program. In 2005, he began what’s grown into a leading Colorado machine shop. Gerry brings over 30 years of machining experience to the shop floor, and is certified in all aspects of geometric dimensioning and tolerancing.

In the increasingly competitive industry of precision manufacturing, combined with current economic conditions, CNC machine shop owners and machinists today MUST have maximizing productivity and increasing efficiency as a central focus. This rings especially true for small and medium-sized operations, including Advanced Precision Machining’s (APM’s) Colorado machine shop. The good news is that we are in the midst of an industrial revolution of sorts (Industry 4.0) and thus far, despite teetering on the edge of recession, the manufacturing sector continues to thrive. Milling and machining work is rapidly transforming and evolving thanks to more advanced equipment, artificial intelligence (AI), robotics, improved process automation, better analytics, preventative maintenance, and the Internet of Things (IoT). Now, machine shops find themselves in somewhat unfamiliar territory. Despite economic conditions,  competition is on the rise, and although the skills gap is shrinking, there still exists difficulty in filling CNC machinist positions. All of this, coupled with increased demand for high quality parts, means that milling and machining facilities must place even greater emphasis on efficiency and productivity. 

Thankfully, more modern technological advancements in today’s precision machining tools mean many machine shops have the ability to streamline their operations. The concepts behind lean manufacturing are now “en vogue”, and more businesses are focused on improving quality, eliminating waste, reducing time and effort, and reducing total costs. At APM, our staff provides CNC milling, turning, prototype development, and more machine shop services in our state of the art facility, and because of sound business practices, we continue to grow. We’ve managed to stay ahead of the manufacturing curve, and in fact, have tripled in size and sales capacity since opening in 2005. But times have changed and competition is up. To remain successful, we are always on the lookout for ways to keep costs down and increase our output, while maintaining the quality, reliability and exceptional customer service our clients have become accustomed to.

The old adage rings more true today than in the recent past…Time is money!  Do you want to make your operation more efficient and productive? No matter the size of the shop floor, there is renewed commonality in the desire for every company to incorporate some frequently described goals that ultimately lead to more efficiency and productivity. We want to use this forum to share with our readers a few of our favorite tips/techniques for improving operations, and most importantly, the bottom line in any CNC milling and machining facility. While by no means an exhaustive list, they should provide you with a clear starting point and set you on the right path to gaining a competitive advantage over your competition.

Improving Organization

It’s amazing the number of man-hours lost and dollars wasted due to a general lack of organization. You must maintain a well-organized place for everything, especially machine tools, and properly put things back into the appropriate place when done. Invest in better tool drawers, cabinets and/or shadow boards for example. Improve your labeling system. Think about the layout of your milling and machining equipment – does it maximize efficiency? Keep the shop floor and equipment clean. This all sounds elementary, but goes a long way to improving efficiency.

Upgrading/Investing in Machine Tools

In reality, machine tools are THE driving force machine shops rely on to make everything work together synchronously and efficiently. Without the right tools for the job, your shop will be treading water. Recent advances in precision manufacturing technology, most notably in the form of computerized numerical control (CNC), computer-aided design and manufacturing (CAD/CAM), greater multi-axis capabilities, and additive manufacturing (3D printing), have led to revolutionary design and production improvements for precision machined parts. Are you on board with the latest and greatest? 

Eliminating Excessive Machine Downtime

Idle machines aren’t making money! A critical way to maximize efficiency is to minimize machine downtime. This goal can be accomplished in a number of ways including: improved run time production planning, organizing parts, investing in cutting-edge machine monitoring software, better preventative maintenance, setting more specific targets, and improving machinist training.

Prolonging Tool Life

The list here can be long. Think about converting to a high-pressure coolant (HPC) system, or increase your existing coolant concentrations. Routinely inspect your tool holders and inserts to avoid catastrophic failures, keep track of the amount of material being removed, and avoid excessive contact time with the workpiece. Think about investing in a harder insert grade if you can. Certain aftermarket coatings, such as aluminum oxide, can help you reduce cycle times while increasing your tool life, feed rates and cutting speeds. Cryogenic machining is also worth exploring and investing in.

Tool Management Systems

Want to keep your tool costs low and your setup times down? Invest in a tool management system (TMS). A good one allows you to seamlessly track and manage your inventory, and  helps eliminate costly over or under-stocking of your tool supply. Companies such as ToolBoss offer a number of systems to regulate and audit tool usage, performance and procurement. Software is even available to track all tools and issue purchasing notices, eliminating costly downtime and saving money.

Want to learn more about improving machine shop efficiency and productivity, or have a question about your next milling and machining project? Contact the expert CNC machinists at Advanced Precision Machining today. 

For more APM machine shop information; Like us on Facebook, follow us on Twitter @APMLongmont, or connect with us on LinkedIn.

About the Author

Gerry Dillon is a co-founder, current owner and certified CNC machinist at Advanced Precision Machining (APM), a full-service machine shop located in Longmont, Colorado. Before making his home in the United States in 2000, Gerry was born and raised in Ireland and took an interest in milling and machining from an early age, ranking #1 in the Irish National Apprenticeship Program. In 2005, he began what’s grown into a leading Colorado machine shop. Gerry brings over 30 years of machining experience to the shop floor, and is certified in all aspects of geometric dimensioning and tolerancing.

The precision manufacturing techniques utilized by today’s machine shops are the result of an industry that’s dynamic and constantly evolving, allowing for the design and production of machined parts that are astonishingly more complex, accurate, and versatile now more than ever. Recent advances in milling and machining technology mean that shop floors similar to Advanced Precision Machining (APM) in Colorado are almost unrecognizable compared to what they once were in terms of specialized equipment and current capabilities. More traditional means of removing material to machine a part relied on a system of cams, mechanical linkages, and some sweat equity, but these historic methods eventually gave rise to what we see today…Highly sophisticated, computer-driven machining centers, lathes, and drill presses. Even newer technology introduced electricity, photochemicals, ultrasound, and 3D printing into the machining arsenal. Add in the progression of computerized numerical control (CNC), CAD/CAM software, and robotics to assist with automating certain tasks, and our industry has truly experienced a revolution!

Now, some nostalgic food for thought. Given all of this cutting edge technology presently in hands of CNC machinists everywhere, are we truly experiencing an improvement over some older ways of milling and machining a part? In almost every case, the short answer is a resounding yes! Surprisingly though, a machining concept introduced over a hundred years ago is having a renaissance of sorts today. Swiss-type lathes, pioneered in Switzerland for the watchmaking industry, are seeing their popularity flourish in recent years and are being increasingly utilized in machine shops running conventional CNC turning machines. Unlike their counterparts from yesterday, state-of-the-art Swiss-type lathes now rely on CNC and automation, and they’re a go-to machine for many high-precision, high-production applications that require accuracy. They’re more powerful than ever, generate faster cycle times, and have much greater flexibility and sophisticated controls that help streamline the machining process. Once seen merely as a specialty tool for one-off custom jobs, many machine shops are realizing the benefits and values Swiss-type lathes bring to the table and are installing this variety of turning technology for the first time. This is due in part to the increased demand for small, complex, low-volume machined parts from the defense, automotive, electronic, and medical parts manufacturing sectors. Machine shop owners the advantages they have over conventional lathes for turning small, intricate and fragile parts, especially those that are long, narrow diameter and cylindrical in nature. In short, CNC machinists are manufacturing parts today that would’ve been unthinkable 5 or 10 years ago on traditional lathes. 

What truly sets Swiss-type lathes apart, resulting in reduced setup times, secondary operations and work in process adjustments, is their specific design allowing for extreme accuracy and ultra-high tolerances. They differ from other lathes where the part is stationary and the cutting tool moves. Instead, Swiss turning lets a part move vertically while the tool remains stationary. The key to this operation is a “sliding headstock” style and a “guide bushing”. To explain, bar stock is held firmly in the machine with a “collet” and advanced, or slid vertically through the guide bushing closely past a stationary, single-point lathe turning tool. Only the portion being machined is exposed from the guide bushing to the cutting tool. This results in great rigidity during the CNC turning process minimizing deflection and vibration while maximizing accuracy and efficiency. In fact, the entire machining process can be completed in a single operation with one setup, reducing the number of times a part is touched during production. The use of live tooling and sub-spindles even allows for overlapping operations. Simply put, with a wide range of capabilities, Swiss-type machining is the most precise and efficient machining method for manufacturing the accurate and critical components customers demand. 

Of course, there are a few drawbacks. As expected, price is a common obstacle causing shops to stop short of adding a Swiss-type lathe to the mix with an average cost running significantly higher than traditional machines There are also some nuances to be learned for a CNC machinist new to the technology, and Swiss-type CNC turning certainly requires deft operation to ensure the demands of tight tolerances are adhered to. The learning curve is steep and requires different thinking regarding axis motion. Most of these machines use oil as the cutting fluid rather than water, so this is a concern when it comes to fire suppression. But, the advantages far outweigh the short list of disadvantages! What began with Swiss watchmakers, then on to screw manufacturers, has now become mainstream. The bottom line is that more and more machine shops have discovered the value of these machines as demand for ever-smaller CNC machine parts has grown. The future for Swiss-type machines will only expand, and machine shops that seek to adopt the technology can distinguish themselves with more high-end work and gain a competitive advantage; What every operation needs in these challenging times.

Would you like to learn more about Swiss-type machining? The discussion above only scratches the surface of this once traditional, but now revolutionary technology. For more thorough information on the benefits of turning with Swiss-type lathes, or if you have questions about your next precision machining project, contact the expert CNC machinists at APM’s Colorado machine shop today.

For more APM machine shop information; Like us on Facebook, follow us on Twitter @APMLongmont, or connect with us on LinkedIn.

About the Author

Gerry Dillon is a co-founder, current owner and certified CNC machinist at Advanced Precision Machining (APM), a full-service machine shop located in Longmont, Colorado. Before making his home in the United States in 2000, Gerry was born and raised in Ireland and took an interest in milling and machining from an early age, ranking #1 in the Irish National Apprenticeship Program. In 2005, he began what’s grown into a leading Colorado machine shop. Gerry brings over 30 years of machining experience to the shop floor, and is certified in all aspects of geometric dimensioning and tolerancing.

No one has to tell machine shop owners and CNC machinists that it’s becoming increasingly more difficult to differentiate their operation in the midst of a precision manufacturing environment that’s experiencing a revolution thanks to evolving technology, new software, and increased connectivity. Add in changing consumer preferences and government policy, and it seems everyone in our industry is feeling the pressure almost daily! Most recently, the economic slowdown we are facing and potential recession mean the months ahead for our nation’s economy and business will remain quite volatile and dynamic. That means staying competitive in the local, national and global marketplace will require even more of a centralized focus on maximizing productivity and increasing efficiency!

This rings especially true for small and medium-sized operations, especially if you add in the lingering effects of the recent COVID-19 pandemic combined with inflation, labor shortages, and recent supply chain issues. To illustrate this point, small business surveys reveal that many business owners are uncertain about the future of their operations. No doubt, today’s economic challenges are unparalleled, but one has to remain optimistic about what the future may hold. At Advanced Precision Machining, we have faced down past operational slowdowns and reduced demand for precision manufactured parts, and we are now experiencing unprecedented growth. We continue to stake our reputation on meeting our clients’ needs for high-precision parts delivered accurately and on-time, all while providing the best customer service experience in the machine shop business!

With all of this in mind, APM’s CNC machine shop is still unable to match the production capabilities of larger rivals in low-mix, high-volume milling and machining work. In order to better maximize profits and achieve our desired growth goals moving forward in these uncertain times means we are consistently in search of ways to gain a competitive advantage. First and foremost, we can’t get ahead without the right technology in hand. Equipped with the latest in cutting-edge machine shop tools from suppliers such as Mitutoyo, Doall, Hurco, ProtoTRAK, Southwestern Industries, and Yama-Seki, we ensure our clients are completely satisfied with our work. But, this extends well beyond the right equipment and resources. There are always better ways of getting the job done! 

This brings us back to what every machine shops’ focus should always center around; maximizing productivity and increasing efficiency. Enter the concept of lean manufacturing; The systematic practice for eliminating waste in the manufacturing process. As facilities around our country strive to resume normal business operations, “lean” will become ever more so important. But for smaller and mid-sized CNC machine shops, the methods central to lean production models don’t always lend themselves well to low-volume, high-mix, and oftentimes one-off precision machining environments. While true, many job shops have successfully adopted this methodology by focusing on the goals and strategies that are feasible to their particular operation. No matter what size, there is commonality in the desire and ability to incorporate some frequently described goals of lean manufacturing. These elements include: improving quality, eliminating waste, reducing time and effort, and reducing total costs. The core objective is to maximize value to the client while reducing waste in its various forms. 

In a manufacturing environment, the 5S workplace organization method is central to the lean manufacturing philosophy. It is a system first utilized by the Japanese to reduce waste and optimize productivity by maintaining an orderly workplace, and it definitely has its place in smaller machine shops. In fact, a typical 5S implementation can reduce the square footage of space needed for existing operations. The 5S pillars of: Sort (organization), Set in Order (orderliness), Shine (cleanliness), Standardize (standardized cleanup), and Sustain (discipline) are indeed scalable to any size facility and provide a template for organizing, cleaning, developing, and sustaining a productive work environment. In short, transition to lean production should not focus solely on equipment, but instead, with the procedures associated with how existing equipment is used.

This begins with a focus on streamlining various processes, and there are many to choose from on the typical precision CNC machining floor. The key is being flexible and adaptable both to the working environment and to the demands of customers. Here is just a small sampling of some possible improvements:

• Reduce excessive inventories, scrap and other waste.
• Incorporate continuous improvement initiatives and investment in quality systems such as shop management software.
• Use quick changeover carts and visual aides such as shadow boards and foam cut outs for organizing tools.
• Eliminate wasted motion and time spent waiting.
• Consider the ergonomics of employees.
• Reduce downtime through better predictive and preventative maintenance.
• Eliminate mistakes, reworks and overproduction of parts.
• Reduce setup times and batch sizes.

Just a sampling to be sure, and what we’ve highlighted is not an end itself, but a means to more streamlined operations by maximizing productivity and increasing efficiency. These are key concepts now, and will become more and more important as economic conditions hopefully improve. Lean is more than simply some best practices, it’s about doing more with less and removing impediments to productivity. By not implementing at least a few lean practices, a machine shop loses its competitive advantage, and future growth, if so desired, will be stymied.

Want to learn more about lean manufacturing, have questions about any of our milling and machining services, or need help with an upcoming project? We’re happy to discuss any need you have, so please contact our Colorado machine shop.

For more APM machine shop information; Like us on Facebook, follow us on Twitter @APMLongmont, or connect with us on LinkedIn.

About the Author

Gerry Dillon is a co-founder, current owner and certified CNC machinist at Advanced Precision Machining (APM), a full-service machine shop located in Longmont, Colorado. Before making his home in the United States in 2000, Gerry was born and raised in Ireland and took an interest in milling and machining from an early age, ranking #1 in the Irish National Apprenticeship Program. In 2005, he began what’s grown into a leading Colorado machine shop. Gerry brings over 30 years of machining experience to the shop floor, and is certified in all aspects of geometric dimensioning and tolerancing.

Despite the recent economic uncertainty gripping our nation, lingering supply chain issues, and labor shortages, Advanced Precision Machining’s (APM) Colorado machine shop is well into the third quarter of what’s been a very successful year for us! Rebounding positively from the COVID-19 pandemic, our milling and machining facility in Longmont, and the industry as a whole, continues to experience growth in all aspects of the business. As the precision manufacturing and metalworking economy has emerged from a somewhat stagnant footing in previous years, we’ve continued with planned expansion and find that our machine tools are now working harder than ever. In fact, demand for our machine shop services has been increasing at a rate that occasionally outpaces our supply and capacity. 

With all of this being said, our mission remains unchanged; We’re dedicated to manufacturing the highest quality precision parts while providing the best customer service experience in the CNC machine shop business! As everyone works to get through this period of economic uncertainty, our CNC machinists are making every effort to meet our customers’ needs for high-quality precision machined parts and deliver them accurately and on-time. Recent advances in milling and machining technology, including a vast array of digital tooling utilities, are now used to augment and boost machine tooling operations, and these are certain to play a big role in meeting the demands placed on us. Today’s modern metalworking facilities now have at their fingertips critical, cutting-edge software necessary to make their business successful, and APM will be relying on it more so now than ever. We are hopeful that our positive growth  continues, and to that end, we want to help educate and familiarize by introducing readers to a sampling of the machine shop software components we rely on for our success.

If one were to take a peek inside any CNC machining facility, you will find a host of technologically advanced software programs being run to improve the productivity of the business itself, and most importantly, the CNC milling, turning, grinding, and measuring machines that are at the very heart of the precision machine work. In addition to the purchase order, scheduling, accounting, inventory, and payroll programs to name just a few, APM’s CNC machinists rely heavily on a natural progression of software suites dedicated to one-off or batch production of precision machine components. From initial blueprint and design, to prototyping, to final part production, the following utilities are standard protocol and used by almost every milling and machining operation. Here we present a brief overview:

Computer-Aided Design (CAD) Software

The CNC machining workflow process cannot begin without the implementation of CAD software; The heavily relied upon technology that allows for the rendering of a 2D or 3D model of a part to be precision manufactured. CAD allows CNC machinists and machine shop customers to digitally create, modify, analyze, and optimize the design of any component before milling and machining work takes place. The precision machining process itself can be facilitated as CAD allows for a part’s materials, tolerances, and dimensions to be analyzed. Diagrams and drawings, or even solid models and prototypes using 3D printing technology, can be viewed and modified prior to production.

Computer-Aided Manufacturing (CAM) Software

Once a part is mocked-up with a CAD rendering, it now enters the toolpath and CNC machine programming phase. CAM software is utilized to organize the CNC machining process. In simple terms, CAM takes the geometric models produced by CAD software and generates a series of codes (G-Codes) that are fed into the control software on CNC mills and lathes, for example. CNC Machinists rely on CAM utilities to form machining strategies that enable workflow efficiency. Selection of stock, dimensions, tool designation, speed and feed settings, and streamlined tool paths can all be programmed into CNC machining centers. CAM works in conjunction with CAD to make the entire part machining process more reliable and more efficient.

Simulation and Verification Software

When G Code is converted in the CAD to CAM process, errors may present themselves in precision machining operations. This is not a good thing! Modern milling machines are complex, and programming errors can result in damage to expensive equipment, wasted bar stock, and loss of time, money and productivity. Simulation and verification software is used to better write, analyze, and improve functions before milling and machining begins. Code simulators and verification programs provide a good graphic replication of how a CNC machine will perform, and what will be produced.

CNC Machine Control, Monitoring, and Other Utility Software

Modern CNC machines consist in part of the machine tool assembly itself, and its computer numerical control system, with control software acting as the heart of the system. Most CNC machining centers, including APM’s Hurco’s VMX 50, rely on OEM software built into the machine that converts CAM programming into the motions of precision machining. Machine monitoring software, such as MTConnect, allows for the exchange of data between precision manufacturing tools and software packages tasked with monitoring the performance of the machine shop equipment. PC-based software also exists that allows for a desktop computer to act as a control unit, although this is more common among hobbyists. Utility packages work in conjunction with control software to monitor performance, output, and capabilities such as part feed and speed.

Shop Management Software

Machine shop management software, such as JoBOSS, is a quoting, tracking and price review software specifically tailored to a precision machining operation. Shop owners are constantly up against short lead times, scheduling conflicts, resource constraints, and many more obstacles to running a lean operation. The right shop management software solution goes a long way towards better handling one-off jobs, blanket orders, multi-level assemblies and split jobs, and helps to automate many outdated, manual processes. The end result is more predictability, shorter lead times, and better allocation of resources, milling machines, and personnel. 

Would you like to learn more? Listed above is only a small, but most heavily utilized, sampling of some common machine shop software solutions. For more thorough information on the software you see described, if you have questions about what you don’t see listed, or you want to put our software power to use for your next precision machining project, contact the expert CNC machinists at APM’s Colorado machine shop today.
For more APM machine shop information; Like us on Facebook, follow us on Twitter @APMLongmont, or connect with us on LinkedIn.

About the Author

Gerry Dillon is a co-founder, current owner and certified CNC machinist at Advanced Precision Machining (APM), a full-service machine shop located in Longmont, Colorado. Before making his home in the United States in 2000, Gerry was born and raised in Ireland and took an interest in milling and machining from an early age, ranking #1 in the Irish National Apprenticeship Program. In 2005, he began what’s grown into a leading Colorado machine shop. Gerry brings over 30 years of machining experience to the shop floor, and is certified in all aspects of geometric dimensioning and tolerancing.