Prototype Machining Secrets: Techniques Top Engineers Use

Prototype machining is one of the most accurate and adaptable manufacturing methods you can use to bring your designs to life. But did you know that achieving top-quality results starts long before the machining begins? It actually starts in the design phase. Applying the design practices we’re exploring in this blog can help you and your engineers improve manufacturability and ensure that every part meets performance expectations — all while staying on budget.

Start with the right CAD software

Prototype machining runs on CAD, so the first order of business is to pick a system that fits your industry and process so you can model, simulate, and adjust parts quickly. The right tool keeps production efficient and revisions simple.

Try to avoid complex features

Intricate geometries can make your part look impressive, but they need additional setups and specialized tools that make prototype machining more time-consuming and expensive. By reducing non-essential details and dividing complex structures into smaller components, you can simplify your design and make your part easier and more cost-effective to machine.

Optimize your part’s wall thickness

Thin walls can cause vibrations during machining, causing your part to have a poor surface finish or fail. But the other end of the spectrum — walls that are too thick — can waste material and add unnecessary weight.

Ideally, you should keep a minimum wall thickness of 1 mm for metals and 1.5 mm for plastics. By maintaining consistent wall thickness in your design, you can minimize warping and ensure stability during production.

Use standard features and dimensions

Designing parts with standard features can significantly cut down on the cost and lead time of prototype machining. Custom dimensions often require special tools or additional programming that can complicate production, so try sticking to common thread sizes (like M6 or M8) and standard hole diameters whenever possible. Also, align features with standard material thicknesses to simplify setup and reduce waste.

Design to reduce setups

Each time a machinist has to reposition a part, production slows down and alignment errors become more likely. The best way to avoid this is by designing your part in a way that minimizes the need for repositioning.

Try to group key features on fewer faces, and design for 3-axis machining where possible. 5-axis machining can handle intricate shapes in a single setup if your project requires more complex geometries, saving both time and effort.

Be thoughtful with tolerances

While sometimes essential, adding tight tolerances unnecessarily can also increase machining costs and also drive up machining costs and extend production time. They’re best applied only to critical dimensions that affect a part’s performance. Meanwhile, you can use general tolerances (such as ±0.1 mm) for non-critical areas.

Fix sharp corners

Cutting tools have a limited radius, making it challenging to make sharp internal corners during prototype machining. While you can use small tools, they can add to machining time and speed up tool wear.  You can simplify the process by adding fillets or rounded corners inside your design.

Be sure to match or exceed the radius of the cutting tool (for example, use a 3 mm or 6 mm radius) wherever possible. By adjusting the radius, machining can go smoothly while reducing stress points to improve the part’s overall strength.

Pick the right material

Material selection plays a big role in cost and machinability. Softer materials like aluminum are easier and faster to machine, while harder materials such as stainless steel or titanium require slower cutting speeds and more frequent tool changes. Not sure what to use? Our experts can help you decide on the right material that balances cost-efficiency with performance.

Partner with a seasoned CNC machining specialist

By working with an experienced CNC partner, prototype machining can go smoothly and become less complicated for your project. Let our team collaborate closely with you. We’ll help refine every aspect of your part, from material selection and tolerances to design optimization. With our expertise and technology, HLH Prototypes Co. Ltd. can turn your ideas into precision-engineered prototypes quickly and accurately.

Let’s take your project to the next stage with our prototype machining service. Start with your free quote and project review by filling out our contact form on this website.