To provide complete solution, we equipped 23 sets CNC Machining Center and 4 CNC Lathe in our die casting shop. This enable us to provide not only the machining for die casting parts , but also provide machining from solid , extrusion , gravity casting, forging, etc.
Get Everything You Need From Sunrise
Sunrise Metal is your one-stop-shop for all your die casting and CNC machining needs. With our added machining process, you can consolidate many services and buy from one supplier. With our CNC machining services, you can find everything you need while receiving a guaranteed high-quality product.
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Tooling: Dies and Molds for Die Casting
Die cast tooling called insert die, die casting dies, or die casting molds, comes in one part each cycle. Sunrise Metal only uses cold chamber die casting machine tooling styles, sizes, and values. Die cast tooling comes in single cavities (one part each cycle) or multiple cavities (more than es or molds for aluminum die cast parts).
Die cast tooling comes in various forms:
1) Die Cast Tooling Inserts
2) Prototype Die Cast Tooling Inserts
3) Unit Die Tooling
4) Complete Class “A” Die Cast Die or Mold Tooling
5) Die Cast Family Mold Tooling
6) Trim Dies for Die Cast Parts
Our In-House Die Cast Tooling Capabiities include:
a. Die casting dies.
b. Die casting molds.
c. Die casting inserts.
d. Die cast tooling modifications.
e. Die cast tooling repairs.
f. Diecast tooling and trim die manufacture.
Die casting is a manufacturing process for producing accurately dimensioned, sharply defined, smooth or textured-surface metal parts. It is accomplished by forcing molten metal under high pressure into reusable metal dies. The process is often described as the shortest distance between raw material and finished photo. The term, “die casting,” is also used to describe the finished part. The term “gravity die casting” refers to castings made in metal molds under a gravity head. It is known as permanent mold casting in the U.S.A. and Canada. What we call “die casting” here is know as “pressure die casting” in Europe.
If you got any questions, please do not hesitate to send us a message. We reply within 24 hours.
When you think of a process as complicated as Computer Numeric Control machining, it is likely that the idea alone will intimidate you. There are many parts requiring perfect programming before it can work for you. It is also complicated to understand how to operate the machinery on a day-to-day basis and you may need to hire help. Besides the fact that it can be very costly to set up and maintain, there plenty of reasons why many companies choose to outsource CNC machining services. This detailed FAQ guide covers questions and answers relevant to CNC precision machining for companies that make this choice.
Let’s go through what CNC Precision Machining is step by step;
CNC stands for Computer Numerical Control. It is the automation of machine tools using computers that execute pre-programmed series of machine control commands. The manufacturing processes utilizes pre-programmed software to dictate the movement of factory tools and equipment.
With this type of machining, three-dimensional cuts are easily accomplished with a single set of prompts. Once the CNC system is activated, the desired cut is programmed into the software and the corresponding tools and machinery to carry out the task, pretty much like a robot.
CNC precision machining can create parts with fine detail and tight tolerances from a variety of materials.
You will find these words used interchangeably as if they bear the same meaning which they don’t. High precision machining refers to the machining of parts with tolerances in the single digit micron range. Ultra-precision on the other hand, involves parts with tolerances in the sub-micron range. High precision if often used and can be found in all the industries CNC machining serves including dental, aerospace, medical, sporting, fluid motion and technology. Mostly, ultra-precision is utilized in the medical field as the need for medical parts to become smaller and more complex increases.
You will come across certain technical terms commonly used in CNC machining, and may not know their exact meaning and where they are uses.
Accuracy means the difference between the real measurements and the measurements from your system. If the difference is minimal then the accuracy of the measurement is deemed to be very high. It may come across as the degree of conformity.
Precision is another commonly used term in CNC machining, and it also defines the reliability of a machine tool. Precision is a measure that defines the capability of a tool to return the same measure again and again. It is the repeatability of a measuring system.
Tolerance can be described as the predictable or allowable deviation of the measurement system from the standard value. Typically, tolerance is measured as +/- 0.01 mm. This means that the measurement if a machine has a tolerance of 0.01 mm, the deviation can either be 0.01 mm extra or less than the standard or known value.
Multi-axis CNC machining can create parts with complicated geometries as they have 2 additional rotational axes. The need for multiple machine setups is eliminated when using 5-axis CNC machining. It allows the tool to stay tangential to the cutting surface so more efficient and intricate tool paths can be followed. This results in parts that have lower machining times and a better surface finish.
5-axis machining refers to the ability of a CNC machining tool to move in five different axes at the same time. Basic CNC machining tools have three main axes: X, Y and Z. Nevertheless, a 5-axis CNC precision machining tool can rotate on two more, A and B axes, to give the cutting tool a multi-directional approach.
CNC precision machining offers great design flexibility but there are various design restrictions mainly related to the basic mechanics of the cutting process. This is the tool geometry and tool access. Most CNC tools bear the cylindrical shape and have a limited cutting length. Due to their cylindrical shape, there could be need to get specialized tools. If you need to get into deeper parts of a cavity, you will need a tool with a longer shaft.
Tool access is another restriction as the cutting tool approaches the part from above. Any features that cannot be seen this way will therefore not be CNC machined. The only exception to this rule is the undercut.
CNC machining can be done as 2D, 3D or even 2.5D. 2D means that the machining process creates a piece that is uniform throughout the blank. No design elements on the piece make it unique as everything is at the same depth and the process can be achieved through milling, laser or plasma cutting.
In 3D CNC machining, there are multiple features on the work-piece and a difference in the depth off the features on the work-piece. There are three axes to cut various depths and create various shapes. There might be an additional 4th axis for more complex shapes and contours.
CNC machining can create simple to complex shapes depending on the consumer’s needs. These products can range from simple 2D shapes to realistic 3D designs.
There are many types of precision machines in the market today using Computer Numerical Controls (CNC). Here is a list of processes used in CNC machining;
This process uses a tool called a lathe that rotates the work-piece on an axis to perform actions such as cutting, sanding, drilling, knurling, deformation, turning and facing using various tools.
This process uses rotary cutters to remove unwanted materials from a part. This is one of the most commonly used methods of machining parts to precise tolerances.
This method involves rotating the work-piece next to a rotating cutting tool. It is often done on lathe machines. Types of turning machining include taper turning, straight turning, threads and external grooving.
The method cuts off excess material using a plasma torch and can be used on a variety of materials including steel.
This machining process uses drill bits to create cylindrical holes in the work-piece. Capabilities of thee drilling process in CNC machining include countersinking, counterboring, tapping and reaming.
Other processes used in CNC Machining include broaching, sawing, grinding, lapping, honing, electric discharge machining, wire EDM, sinker EDM and water jet cutting.
Turning operations in a CNC machine are performed by rotating the work-piece and using a cutting tool while milling is done by rotating the cutting tool on a stationery work-piece. Turning is preferred when creating parts that have cylindrical or symmetrical features. It can be very efficient when running high volume production on a CNC lathe. One may add a bar feeder to automate the process and reduce manual activity by the operator.
Milling is preferred when a part does not have any important cylindrical features. On a 4 to 5 axis machine, it is easy to rotate a work piece on automatically for more complex shapes and contours.
CNC Machining involves removing material layers at a time and can allow for many different materials to be used with few limitations. Also, because it is computer controlled, it can only withstand very precise tolerances. Injection molding, on the other hand, involves injecting material into a mold by melting the stock material and forcing it into the mold at high pressure. It is then ejected from the mold.
CNC Machining allows an engineer to have more flexibility in their design. It is easy to create features with machining that could be quite difficult or costly in injection molding. Some of the designs include large walls with no drafts and overhangs.
When one desires low volume, CNC machining is much faster. It takes time to make a mold before injection molding begins and that is can cost time and money. CNC machining is also compatible with a large assortment of materials ranging from plastics to woods. Injection molding, on the other hand, has more limited material options as one needs to melt the original materials into a liquid first.
The main difference between CNC Precision machining and 3D printing is a form of additive manufacturing while CNC machining is subtractive. CNC machining starts with a block of material known as a blank and cuts off the excess material using cutters and spinning tools to form the finished product. 3D printing involves creation of parts that are made layer-by-layer using materials like FDM, SLA/DLP, plastic and metal powders. Using a source of energy like a heated extruder or laser, the layers are solidified to form the finished product. Some advantages of CNC machining over 3D printing is that it can use range of materials and offers great dimensional accuracy.
Those familiar with both processes will agree that each has its own benefits and limitations. CNC machining can create molds and parts in any size. The size is only limited by the capacity of the machining tools available. Machining must deal with every feature in a part which may add time and cost. However, it has an advantage on feature detail over Rapid Prototyping as it excels in smooth edges, blends and chamfers.
The most notable advantage of rapid prototyping is its ability to quickly and efficiently create complex parts. There are situations where Rapid prototyping may be better than CNC in producing features like sharp corners or deep channels. It has fewer steps, less labor and does not care for design complexity reducing lead-times for the entire project. It may not be the fastest for all types of parts but it tends to be more efficient in labor and time.
The history of precision machining dates back 1800s when the need for extremely accurate parts arose with the industrial revolution. John Parsons is considered the father of CNC machines. He conceived and implemented the idea with the help of an aircraft engineer Frank L. Stulen in 1940. Parsons was the son of a Michigan manufacturer and began working in his father’s factory at 14.
CNC Precision machining can be used to produce complex parts in about any type of application across any industries. It provides high levels of accuracy on short and high runs creating parts that identical in quality regardless of whether the shop makes one or a thousand to finish the order.
Here are some of the industries that require CNC machined products;
The products that can be made of a CNC machine depend largely on the type of machine in question. As each machine boasts its own accuracy level and machining sequences, each type of machine is used for producing a unique nature of components. Some of the products that a CNC precision machine would create include wooden chairs, aviation parts, auto parts, wood or metal decorations, plastic pieces, and steel aerospace parts for shuttle.
The accuracy of a CNC precision machine depends on two factors – the tolerance and precision. Machine precision is mostly affected by the software driving the machine. Wear in these machines can make them assume the exact physical properties of all the operating components leading to imprecision.
The accuracy is measured by tolerances that it can achieve when cutting a part. The factors that can affect the tolerance include:
Usually a tolerance of 0.001 inch is considered good. To measure the accuracy, you measure the finished part in micrometers and the deviation from the desired dimensions are calculated.
This is a broad question as the size and detail of the work-piece greatly determine the time it takes to machine the part. For small runs, the job is usually completed in a day. Bigger production runs will require more time. Check with a CNC machining expert to know the time it may take.
Despite the customizability and versatility of the process, the manufacturing of some large or heavy parts may present more challenges than others. Sunrise Metal possesses superior engineering capability and can offer a complete solution in any of their 23 machining centers. The company further operates 4 lathe machines in the die casting shops to provide machining for all kinds of parts. This reliable one-stop service can run high mix, low to medium volume projects in half the time taken by other companies due to its high capabilities.
Below are 7 benefits for using and outsourcing CNC precision machining in your business;
Once you key in the right specifications in a CNC machine, the rest of the automated process takes over. The chances for mistakes in this kind of set up are minimal when compared to human machining. Outsourcing this kind of job means that you will not require you to hire staff to run the machines.
The concept utilized in precision machining is subtraction this there is potential for a lot of material waste from a single product throughout the process. CNC precision machining can reduce this type of material wastage when compared to human error. With contract companies, you may be buying bulk material thus saving even more.
With this type of machining, you get a consistent quality output with every product as long as the design is the same. Consistently creating the same quality of product leads to customer satisfaction and enhances brand awareness.
If the engineer’s time and skills are spent in the creation of the actual product and not tiny changes, CNC machining is fast. Contract companies are able to make minor detail changes and can assist with modification during the prototyping process.
By using contract machining services, you can reduce your turnaround time as a contract company is experienced in the type of work. They have large systems on place to get the job done as fast and as efficiently as possible.
Having a faster production cycle means that you are able to offer your product faster to the market. This may give you an edge over companies using old methodologies and you might have more flexibility to work with customer requests and adjust to meet industry regulations.
There are two ways that CNC machining can make it easier to test prototypes. One is that it may help a company explore smaller markets and if there is a market, the company can scale to full production. Also, CNC machining helps prototypes have functional parts rather than a concept prototype. Functional prototypes offer more confidence from investors than concept-prototypes.
The general limitations of CNC Machining are;
A full set of CNC instructions can be performed continuously without manual invention in a precision machine shop. The first step is to produce a computer-aided design (CAD)of the final product. A CNC programmer utilizes computer-aided manufacturing (CAM) software to design the steps the machines will follow to create the finished product. The manufacturing process utilizes different tools, machines and even robotic arms to move the parts from one machine to the best. The basic CNC machining includes the following stages;
CNC Precision machining is used widely in many industries. CNC precision machining services are available to small, medium and large corporations in industries such as medical, aerospace and government. Precision CNC machining services can also include CNC prototyping, special blanket orders and smaller production runs.
Despite the customizability and versatility of the process, the manufacturing of some large or heavy parts may present more challenges than others. Sunrise Metal possesses superior engineering capability and can offer a complete solution in any of their 23 machining centers. The company further operates 4 lathe machines in the die casting shops to provide machining for all kinds of parts.
When it comes to CNC precision machining, the advantages are plenty and the technology has been tried and tested. However, getting the right service provider can still prove difficult for companies. The best manufacturer is able to take you from concept to product realization giving you money and time-saving advice throughout the journey.
When choosing a machining service, you should ensure they have the tools needed to offer a full range of services. Here is what to look for before engaging with a service;
Experience: You really want to be sure that your manufacturing company has a good reputation and has been in business long enough to understand what they are doing. Sunrise Metal has been in the business for over 10 years.
Compliance: Make sure that your company adheres to state and international regulations. Check for ISO 9001-2015 certification which is the standard created to ensure highest levels of management. Sunrise Metal has both ISO 9001 & IATF 16949 certifications.
Comprehensive Customer Support: You might need a lot of help during the early stages of conceptualizing your product. Without a responsive customer care, it will be difficult to iron out any problems with your design and you will be stuck with a product until the company can get to you. Sunrise Metal is ready to respond to your questions in a jiffy. We have a fast customer care team and promise to respond in less than 24 hours.
Little to No Delivery Delay: When you get into full working mode with your machining service, there should seem to be little separation between their process and yours. The two companies are working hand in hand and it is vital that they can deliver finished products at a predictable pace.
Almost any material is suitable for use in CNC precision machines. It depends on the application but there are common materials like aluminum, copper, brass, titanium and steel alloys including 1018, 1215, 12L14. The most popular aluminum material for CNC machining is Al6061. This is the most widely used alloy in Sunrise Metal as well. 6061 contains silicon and magnesium, which gives it great properties. It has good weld ability, great mechanical properties, accepts coatings well, boasts high resistance to corrosion and is readily available.
Other materials that are commonly used include wood, fiberglass, foam and plastics like ABS, POM (Delrin), PTFE (Teflon), PC, nylon and polypropylene.
Typically, this may vary depending on the manufacturer. Basic guidelines dictate that there are minimum thickness requirements to enhance cosmetic appearance, improve part manufacturability and reduce overall production time. You will find that most machines can maintain tolerance of +/- 0.1mm. Parts can be as thin as 0.5mm as long as the nominal part thickness is more than 1 mm. For specific milling dimensions by material and design, it would be beneficial to talk to CNC machining experts for solid advice.
Due to the nature of CNC precision machining, machined parts can have minor tools marks on the surface after machining. There are several methods used to enhance the surface roughness, wear resistance and attractiveness of the CNC machined parts. Here are the most commonly used surface finishes for different applications:
This is the fastest way to finish your surface with CNC machining. Parts that have sharp edges, blurs and minor tool marks can be removed fast upon request.
This type of surface finish adds a layer of satin or uniform matte on a machined part to erase tool marks. This is mainly done for visual attractiveness.
The process involves the use of powdered paint sprayed onto a part then it is baked in an oven. This creates a durable wear and corrosion resistant layer that is stronger than standard painting. When compared to anodizing, powder coating has a higher impact resistance. This surface finish can be applied on any metal and is available in a wide range of colors.
Type II adds a layer of corrosion-resistant ceramic on the surface of the machined part. It can be dyed to any color with black, gold, red and clear being the most common colors. It is usually associated with titanium and aluminum.
Type III adds a layer of corrosion and wear resistant ceramic to the surface of the machined part. The layer is thicker and offers better protection than type II. It can only be used on titanium and aluminum.
This process uses an electric current to dissolve unwanted metal cations to create a thin coherent metal coating on an electrode. The coating film will help to prevent corrosion and improve wear resistance, refection, conductivity and attractiveness.
CNC machining experts can advise on other finishes available if you have not seen one you like. Simply ask for custom finishes.
Technical drawings allow engineers to communicate effectively and can be kept as a record of the planning process. They say that pictures are worth a thousand words. In engineering, a technical drawing is just as effective a written plan.
Modern CNC machines are able to interpret the geometry of any part directly from the 3D cad file. You will not need a technical drawing to request a quote but they are still vital. Technical drawings can drastically improve the communication of technical requirements between the engineer or designer and the machinist.
It is important to include these in your 3D CAD model as they cannot be conveyed in a CAD file;
There are reasons why it is important to accompany your request with a 3D CAD file;
There are important steps in creating a technical drawing. Here is how to do in 7 easy steps;
CNC setups are different and every machine may need different formats. However, there are general file formats that most machines can work with. The most commonly accepted formats for CAD files are PDF, AI, DXF, DWG for 2D files, STL, STEP, DXF, IGES and 3DM for 3D files.
CNC Precision machining clients can communicate what they desire to create with a technical drawing. While a CNC precision machinist is able to create a drawing, it would be easier to approach them with something to work with. This way, they can make modifications for you where necessary and guide you accordingly.
If you have no CAD file, Sunrise Metal can create one for you, as it may be required for future reference. Sunrise Metal can create design proposals and create mechanical parts at the design stage. The company is able to provide DFM (design for manufacturing) and PPAP in tooling stage. At the production stage, an expert from the team is able to provide problem solving and cost saving suggestions. With these systems in place and this kind of support, your projects are bound to run smoothly within the whole life cycle.
You may have come across ISO 9000 certification in CNC Precision management. The most recent is ISO 9001: 2015 which is centered around 7 quality management principles: customer focus, process approach, leadership, improvement, evidence-based decision making, relationship management and engagement of people. When choosing a CNC machine firm, the ISO 9001:2015 proves the most useful of all certifications to consider as it is a foundation for companies to build relationships with their customers.
Several factors can affect your manufacturing costs and a few tweaks can have significant impacts on cost.
There are changes one can make to the above-mentioned factors reducing the ultimate cost of CNC machining. Here are our top tips;
Sharp 90-degree corners make machines stop for the part to be rotated the machining can continue. These additional steps can take more time and ultimately cost you more money. Make changes to the corner designs changing them from corners to rounded edges.
Deep pockets impact the cost of CNC machining negatively as it is time-consuming to remove material. It may also require the use of special tools to achieve the required depth. While CNC machines do not have a limit on the depth they can create, it will cost you more money to do this.
If your part requires a tight tolerance, the cost of making this part increases as it needs manual inspection and more machining time. Tight tolerances are hard to achieve internally and machining cavities can create burrs on edges, which require another step for finishing.
The more decimal places you include, the more precise the tool and the higher the cost. Ensure you remove the unnecessary decimal points from your design.
Thin walls take more time machine because they are fragile. They are machined through multiple passes with low setting depths to avoid any fractures or errors. Thicker walls are more stable and cost much less to machine.
Threads that are longer than required may end up costing more because of the special tools required to create them. Any thread longer than 1.5 times the diameter of the hole will not make the connection any stronger. Reduce CNC machining costs by setting the length of thread 3 times the hole diameter.
If you have a complex part that needs rotating and repositioning, machining your part may involve a custom fixture, repositioning, manual rotation or a multi-axis CNC system, which translates to more money. If you cannot make the part less complex, then try splitting the part into two to reduce your CNC machining costs.
The surface finish you choose protects the CNC machines from harsh environments and often also enhances the appearance. Choosing multiple finishes for one part will drive the cost quite high so if you have no need for surface finishes, request the as-machined finish to save money.
The number of parts you require has a direct impact on the unit price. Increasing the quantity from one to 50 may decrease the unit price by more than 50%. Consider ordering in bulk the next time you place an order.
With proper quality control and limited labor costs, CNC technology has seen manufacturers increase profitability. Beyond what we have now as CNC precision machining, we may be looking at next-generation computer numerical controls that have virtual; reality for CNC programming, advanced automation and programming of additive manufacturing and robotic assembly of microstructures, and advanced CNC intelligence. We can expect more opportunities when it comes to sophisticated multi-material assemblies as advanced automation increases printing speed and precision.
It may also eliminate the need for finishing or secondary processing of some materials as advancement with material sciences provide better solutions for finer finishes in a single machine.
CNC 3D printers are advanced machines that are changing how manufacturing happens. Businesses and consumers can easily make a prototype using custom tools. The future of CNC machining may combine the perks of 3D printing and CNC precision machining to create functional 3D CNC machines that are easy to use and maintain.
In a nutshell, we can expect more trading as machines will be capable of more functions. We can expect better connectivity between CNC machines, which will rely less on human operators. Further, look out for dealers who will create more innovative support services and offer expert advice to manufacturers for a seamless manufacturing experience.