Boosting Your Project s Performance with Low Volume CNC Machining

What Is Low-Volume Manufacturing?

In terms of cost, low-volume manufacturing typically has higher per-unit costs compared to high-volume manufacturing. There are several factors that contribute to this cost difference:

Economies of Scale: The advantage of high-volume manufacturing lies in economies of scale, which lead to a reduction in the cost per unit as production volume rises. This is due to the distribution of fixed costs like tooling, setup, and equipment across a larger number of units, thereby lowering the cost for each unit. Conversely, low-volume manufacturing misses out on these economies of scale, which leads to increased costs per unit.

Tooling and Equipment Costs: High-volume manufacturing often involves the use of specialized tooling and equipment that may require significant upfront investment. These costs are distributed over a large production volume, reducing the cost per unit. In low-volume manufacturing, the cost of tooling and equipment is spread over a smaller quantity of units, leading to higher per-unit costs.

Benefits of Aluminum CNC Machining:

Lightweight: Aluminum is known for its low density, making it an ideal choice for applications where weight reduction is crucial. CNC machining allows for the creation of lightweight aluminum components without compromising on strength or structural integrity.

Excellent Machinability: Aluminum alloys, including 6061 and others, exhibit excellent machinability. They can be easily shaped, cut, drilled, and milled using CNC machines, leading to efficient and cost-effective manufacturing processes.

Good Strength-to-Weight Ratio: Aluminum alloys offer a favorable strength-to-weight ratio, providing sufficient strength and structural integrity while keeping the weight of the finished part relatively low. This makes them suitable for applications where both strength and weight reduction are important, such as aerospace or automotive industries.

Materials for Custom CNC Machining Parts
A wide range of materials is available for CNC machines, offering versatility for rapid prototyping and custom production of intricate parts. We offer instant quotes for over 150 metals and plastics to meet your manufacturing requirements, allowing you to compare costs across various processed materials.
	ALuminum Aluminum is a highly ductile metal, making it easy to machining. The material has a good strength-to-weight ratio and is available in many types for a range of applications.	Aluminum
		Machinable Material Types	AL6061-T6,AL6063-T6,AL6082 AL7075-T6,AL5052-H32
		Lead Time	3 days
		Tolerances	±0. 01mm
		Max part size	200 x 80 x 100 cm
	Copper Copper displays excellent thermal conductivity, electrical conductivity and plasticity. It is also highly ductile, corrosion resistant and can be easily welded.	Copper
		Wall Thickness	0. 75 mm
		Lead Time	3 days
		Tolerances	±0. 01mm
		Max part size	200 x 80 x 100 cm
	Brass Brass has desirable properties for a number of applications. It is low friction, has excellent electrical conductivity and has a golden (brass) appearance.	Brass
		Wall Thickness	0. 75 mm
		Lead Time	3 days
		Tolerances	±0. 01mm
		Max part size	200 x 80 x 100 cm
	Stainless Steel Stainless steel is the low carbon steel that offers many properties that are sought after for industrial applications. Stainless steel typically contains a minimum of 10% chromium by weight.	Stainless Steel
		Machinable Material Types	304 SS, 303 SS, 316 SS, SS 430F, 301 SS etc.
		Lead Time	3 days
		Tolerances	±0. 01mm
		Max part size	200 x 80 x 100 cm
	Titanium Titanium has a number of material properties that make it the ideal metal for demanding applications. These properties include excellent resistance to corrosion, chemicals and extreme temperatures. The metal also has an excellent strength-to-weight ratio.	Titanium
		Wall Thickness	0. 75 mm
		Lead Time	3 days
		Tolerances	±0. 01mm
		Max part size	200 x 80 x 100 cm
	Plastics Plastics are also a very popular option for CNC machining because of its wide choices, relatively lower price, and significantly faster machining time needed. We provide all common plastics for CNC machining services.	Plastics
		Machinable Material Types	Buff ABS, Black ABS, Clear ABS, 94V0 flame retarding ABS, ABS+PC, Black Polycarbonate, Transparent Polycarbonate, Acrylic, NYLON 6, NYLON 66, PA6+30%GF , HDPE, POM, PP, PP+20%GF, PE, TEFLON,PPS, PEEK, PPO, PPE, PEI
		Lead Time	3 days
		Tolerances	±0. 01mm
		Max part size	200 x 80 x 100 cm

How To Choose The Right Rapid Prototyping Technique

Material Costs: Material costs can also differ between low-volume and high-volume manufacturing. In high-volume production, manufacturers may have the advantage of bulk purchasing, negotiating better material prices, and taking advantage of long-term contracts with suppliers. These factors can help reduce material costs per unit compared to low-volume manufacturing.

Efficiency and Automation: High-volume manufacturing often involves greater automation and optimized production processes, leading to higher efficiency and reduced labor costs per unit. Low-volume manufacturing may require more manual labor, setup time, and customization, leading to higher labor costs per unit.

Heat Treatable: Aluminum alloy 6061 is heat treatable, which means it can be strengthened through heat treatment processes such as solution heat treatment and aging. This allows for further enhancing the mechanical properties of the machined parts, including increased strength and hardness, while maintaining good machinability.

Versatility: Aluminum alloy 6061 is highly versatile and can be used in a wide range of applications. It is suitable for machining complex parts with intricate designs, making it a preferred choice for CNC machining processes. It can be easily formed, welded, and joined, providing flexibility in manufacturing and assembly.

How To Process Low-Volume Manufacturing

Success in low volume manufacturing hinges on the strategic production of small product batches, which may vary from a handful to tens of thousands. The main objective is to reduce expenses associated with tooling, labor, and materials, while not sacrificing the speed of production or the quality of the product. Achieving this balance involves optimizing processes and choosing cost-effective resources. Low volume manufacturing is ideal for specialized or custom products, as it allows for quick market introduction and design adaptability, all while cutting down on overhead costs.

In the realm of raw materials, low-volume manufacturing exhibits distinct preferences. Metals such as steel, aluminum, brass, and copper are chosen for their durability and resistance to wear, while plastics like ABS, nylon, and polycarbonate are selected for their lightweight, adaptability, and cost-effectiveness.

In terms of processing methods, technologies such as additive manufacturing (3D printing), CNC machining, and rapid tooling are advantageous for low-volume production due to their reduced costs and faster lead times. Moreover, low-volume manufacturing ensures the quality of the end product by cost-effectively producing high-quality parts, and it permits extensive customization to fulfill specific customer needs.

Our clients often express concern that low-volume manufacturing might compromise quality or precision in comparison to full-scale production. However, we assure you that our lower volume orders are processed with the same materials, equipment, and stringent quality control measures.

How is this achieved? We specialize in high-mix, low-volume production, with systems designed for scalability, from a single unit to millions. Our robust supply chain ensures a steady flow of raw materials, eliminating minimum order volume constraints. Additionally, our digital manufacturing platform integrates all equipment into a unified network, enabling swift and efficient resource allocation across work centers, ensuring even complex orders are processed rapidly.

What Separates Barana Rapid’s Inspection Processes from the Rest?

Precise measurement, inspection, and testing are essential to guarantee the conformity of your components. We conduct multiple inspections at each stage of the product development process, from the verification of incoming materials to the final 3D scanning. You will be provided with comprehensive digital files and Certificates of Compliance to help you achieve your regulatory and performance objectives.

Inspections and Reviews at Every Production Stage

To maintain quality throughout the entire process, Star Rapid offers the following inspection and review services:

Thorough verification of incoming materials

Design for manufacturing reviews with every quote

Contract reviews following the receipt of purchase orders

First article and in-process inspections

Final inspections and testing, complete with detailed reports and necessary certifications