How to Optimize Part Design for CNC Machining Cost Reduction

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In the competitive world of custom part manufacturing, controlling costs without compromising quality is paramount. For businesses relying on CNC machining, a significant portion of the final part cost is determined not on the shop floor, but during the design phase. By incorporating Design for Manufacturability (DFM) principles, engineers can dramatically reduce CNC machining expenses, accelerate lead times, and enhance part reliability. Here are key strategies to optimize your part design for cost reduction.


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1. Simplify Geometry and Minimize Complex Features
The most straightforward rule is that complexity equals cost. Intricate 3D contours, deep cavities, and sharp internal corners require specialized tools, multiple setups, and significantly more machining time. Whenever possible, design with standard tool geometries in mind. Use larger internal corner radii (fillets) instead of sharp 90degree angles. This allows the use of larger diameter cutters that can remove material faster and more efficiently. Simplifying the overall shape reduces programming complexity and cycle time.

2. Strategically Select Materials
Material choice is a major cost driver. While highperformance alloys like titanium or Inconel are necessary for some applications, they are expensive and difficult to machine, leading to rapid tool wear and long cycle times. If your project allows, opt for more readily machinable materials like aluminum 6061 or brass. These materials can be machined much faster, saving on both machine time and tooling costs. Always consult with your manufacturing partner early to select the most costeffective material that meets your functional requirements.

3. Standardize Hole Sizes and Threads

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Custom, nonstandard hole sizes and thread types necessitate special tools and increase setup time. By designing holes and threads to standard drill bit and tap sizes, you leverage the tools that are already in the machinist's standard inventory. This eliminates the need for custom tooling, reduces the risk of errors, and streamlines the entire process.

4. Avoid Deep Cavities and Thin Walls
Machining deep cavities requires longreach tools, which are prone to deflection and vibration. This often results in slower feed rates, multiple passes, and potential inaccuracies. Similarly, designing thin, tall walls can lead to chatter and part deformation during machining. Increasing wall thickness and limiting cavity depth to four times the tool diameter enhances stability, allows for more aggressive machining, and improves the overall quality of the final part.



5. Design with Tolerances in Mind
Specifying unnecessarily tight tolerances across all part features is one of the fastest ways to inflate costs. Tighter tolerances require slower machining speeds, additional finishing operations, and more precise inspection, all of which add time and expense. Apply critical tolerances only where they are functionally essential for the part to mate with other components. For noncritical features, use standard, looser tolerances to maintain efficiency.

Partner for Success
At our company, we specialize in providing expert DFM feedback. By collaborating with us from the initial design stage, you can leverage our machining expertise to create parts that are not only highperforming but also highly costeffective. Optimizing your design for CNC machining is a powerful strategy to maximize your budget and drive your business growth. Contact us today to see how we can help you build better parts for less.