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Optimizing CNC Designs: Sharp Corner Techniques

Sharp corners can be challenging to create with CNC prototyping. But don’t worry—this doesn’t necessarily mean that you need to redesign your product or use another manufacturing technology. At HLH Prototypes, we will collaborate with you to make your part more suitable for CNC machining.

Why avoid sharp corners?

CNC machining can be used to carve designs into blocks of metal or plastic using rotating tools like drill bits and end mills. The problem is that these tools are round, limiting how sharp they can cut corners (especially inside pockets). The size of the tool’s rounded tip determines the smallest possible corner radius we can achieve, and this radius directly affects the final quality of your part and how long it takes to make.

If you want a clean and sharp corner, the tools need a 90-degree path, but CNC tools are not designed that way. If we proceed, we need to stop the machine to pivot the workpiece. However, this increases the risk of chatter marks (faint ripples) because the tool vibrates and slows the machining process.

How we solve this problem

At HLH Prototypes, we can use the following techniques to overcome sharp corner issues during CNC prototyping:

  • Adding a corner radius or filet: This increases the radius of the corners.
  • Dogbone and T-bone filets: For parts that need to fit together perfectly, we can add tiny ramps or bumps at the corners instead of a sharp edge. These gentle slopes allow the parts to slide together seamlessly, even though the corners themselves are slightly rounded.
  • Sink and wire EDM: This removes material from the workpiece using recurring electrical discharges. This makes it possible to machine parts with complex geometries.

Talk to us!

Our in-house experts are ready to offer tailored design tips for CNC prototyping. Contact HLH Prototypes by calling +86 755 8256 9129. You can also get a free quote and project review by submitting the form here.

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