CNC Prototype Machining
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  • CNC Prototype Machining

CNC PROTOTYPE MACHINING

WayKen is expert in CNC prototype machining service in China for the finest, highly accurate visual design models, full-functioning engineering prototypes or master patterns.

Fast turnaround and high caliber CNC machined parts can be fulfilled with a wide variety of materials, including production plastics, metals and other composites.

Short for Computer Numerical Control, CNC is the automation of machine tools by means of computers executing pre-programmed software dictates the movement. CNC machining is optimal for one-off custom parts and is available in machining virtually any block material directly according to your 3D CAD data.

WayKen offers CNC milling, CNC turning, drilling and tapping for a variety of materials, such as metal machining or CNC plastic. Quick-turn CNC machining works best for rapid prototyping, forming and fit testing, jigs and fixtures, and functional components for end-use applications.

PROTOTYPE CNC MACHINING SERVICES IN CHINA

CNC rapid prototyping is used to create plastic prototypes and metal prototypes, which allows your design team to closely simulate the final product appearance and function, and also reflecting the validity of physical dimension and the ease or complexity assembly work, and yet give the space to modify and optimize design.

We custom-configured our CNC milling machines and CNC turning lathes for complete integration with all the CAD/CAM software systems, to significantly streamline and simplify all of our CNC machining processes. We are very efficient in keeping up with clients’ demanding production schedules while being able to handle the operation of various machining projects that require precise tolerances, special materials, complex parts, and optimal efficiency.

3-axis machines for short production runs or simple components, flexible 4, 5-axis configurations for precision machined components, and optimized workflows of NC programming and tool path, all go beyond traditional setups and machining practices, and ensure us to perform complex machining tasks in specifications on time.

CNC MACHINED PLASTIC PARTS

Although there is no definitive meaning of plastic precision machining, we custom-configured it while accurately and repeatedly producing challenging parts in terms of geometry, high tolerances, optical clarity and various finishes. CNC plastics machining is very different from metal machining. Different materials come with different challenges so it requires a different way in terms of tools selection, running parameters, and advanced milling techniques.

Meeting these requirements requires superior equipment, and high performance machines, tools and cutters, efficient programming and processing, experience and a culture of only accepting the highest quality. Throughout the machining processes we also conduct the overall process inspection to ensure quality is built into and maintained in all aspects. We are experts in a versatile range of techniques and methods of custom plastic machining.

CNC MACHINED METAL PARTS

Apart from machining plastic components, WayKen also offers metal CNC machining that meets any complex design specifications. It encompasses turning, milling, drilling and tapping for a variety of metal materials.

Most CNC metal parts are made of various grades of aluminum, magnesium alloy, zinc alloy, carbon steel, stainless steel, copper or brass. Some features, such as square cornered keyways, can be difficult to machine and may involve the use of EDM or wire EDM.

We analyze your design and accommodate any special fixturing and machining strategies used to produce your parts at a very reasonable cost. We are capable of doing secondary operations like anodizing, painting, powder coating, heat treatment, sand blasting and polishing.

5-AXIS CNC MILLING CAPABILITIES

When mentioned a standard 5-axis machine, it refers to the number of directions in which the cutting tool can move, that after setup the cutting tool moves across the X, Y and Z linear axes and rotates on the A and B axes, simultaneous milling and machining, and with high-quality surface machined finish. This allows the complex and intricate parts or parts featuring multiple sides can be processed up to five sides of a part in a single setup. This supports design engineers to design multifaceted parts that can enhance the functionality and performance of the final product without limited process.

As many parts produced in prototype shops these days require five-sided machining, 5-axis milling and machining services are in high-demand for various applications in a wide range of industries including aerospace industry, steamer industry , car refitting industrial as well as energy production industries. Machining benefits include higher-quality surface finish, positioning accuracy, and short lead time while creating a tremendous edge for new business opportunities.

Advantages of 5-Axis CNC Milling

High-quality surface finish: It is feasible to produce high-quality machined finish parts with the use of shorter cutters with a higher cutting speed, which can reduce the vibration that frequently occurs when machining deep cavities with a 3-axis process. It makes a smooth surface finish after machining.

Positioning accuracy: 5-axis simultaneous milling and machining has become crucial if your finished products must adhere to strict quality and performance specifications. 5-axis CNC machining also eliminates the need to move the work piece among multiple workstations, thereby reducing the risk of error.

Short lead times: The enhanced capabilities of the 5-axis machine results in decreased production times, which translate into shorter lead times for production compared to the 3-axis machine.

CUSTOM LOW-VOLUME CNC MACHINING

Custom low-volume CNC machining is one supplement between prototyping and mass production, it is good purposed for trail order and marketing testing. Manufacturing in low volumes in CNC machining is also one good assessment solution for the coming mass production schedule. Based on this reason, more and more companies decide to use low-volume production because it gets products to the market quicker. At the same time, it also can create more room for improvement on products depending on the feedback of the uses.

From rapid prototype to low-volume production, this stage has become a development trend in CNC machining industries today. It can not only rapidly improve the capabilities of most manufacturers, but also reduces risks in facilitating design flexibility and saves on-production time and cost.

The combination of superior equipment and the unsurpassed knowledge and experience of our team members gives us a tremendous edge for short running production quantities.

For over years, WayKen has served customers from diverse industries by manufacturing high-quality, precision milling parts. We offer both custom CNC prototyping services and low volume machining services with our professional technology.

We are truly your one-stop services in China for all of your machining projects. Whether you need simple parts, complex components or several different parts, WayKen is standing by you to manage any mix of parts and volume.

WAYKEN’S CAPACITIES FOR CNC MACHINING SERVICES

WayKen has a team of professional engineers and machinists to reduce redundancy, optimize CNC programming, shorten machining time, improve surface, thus we could ensure parts are machined coming out with the best possible product results, our manufacturing team is absolutely strict when it comes to quality and attention to detail.

The state-of-the-art 3-axis and 5-axis CNC machines are backing up the team to have quick run of CNC plastic machining and CNC metal machining separately and quickly, all the parts are manufactured on our wholly-owned facilities, which gives us complete control from design to manufacture of our CNC machining process.

 

CNC machining is one of the most critical processes in manufacturing, from the production fasteners to automotive parts and aerospace components. Having satisfied various clients across the industrials, WayKen gained a great experience and broad knowledge on how to make parts exactly as what the customer’s specifications asked for, and understood the importance of on time delivery. WayKen could offer fast turnaround of 3-9 business days.

What you can’t see does matter, at WayKen, not only do we produce high quality components, but we also offer project management to our clients, providing proper advice on design for manufacturing, to assist your project succeed at early stage. Our project management team is the best in the world. Complete control of design and manufacturing means there is only one source of accountability. You don’t need to go to multiple factories to get the assistance you need. Furthermore, our one-stop total customer care system supports our production team so they can get their job done efficiently and perfectly. If you have any issue, we make it right.

TOLERANCES & MATERIALS

CNC Machining Tolerances

WayKen’s general tolerance is applied to DIN-ISO-2768 (medium) for machined plastic and DIN-ISO-2768 (fine) for machined metals. Typically, we can hold a machining tolerance from +/-0.005" (+/-0.125mm) to +/-0.002" (+/-0.05mm). Part features are recommended to be thicker than 0.02" (0.5mm) in all regions and a nominal part thickness above 0.04" (1.0mm) is required. If tighter tolerances are required, the information must be communicated as to which dimensions require a more narrow range, overall geometric tolerances can be applied to the drawing for the part.

Tolerances are greatly affected by part geometry and type of material. Our project managers will consult with you on every part of your project and will provide the highest degree of precision possible.

It is important to keep in mind that a tighter tolerance can result in additional cost due to increased scrap, additional fixture, and/or special measurement tools. The best way to apply tolerances is to only apply tight and/or geometric tolerances to critical areas, which will help minimize cost.

CNC Machining Material Selection

  • ABS - (Natural / Black / Flame Retardant)
  • ABS / PC Blend
  • PC / Polycarbonate - (Clear / Black)
  • PMMA / Acrylic - (Clear / Black)
  • PA / Nylon - (Natural / Black / 30%GF)
  • PP / Polypropylene - (Natural / Black / 20% GF)
  • POM / Acetal / Delrin - (Black / White)
  • PVC
  • HDPE
  • PEEK
  • PEI / Ultem
  • Bakelite Resin
  • Epoxy Tooling Board
  • Aluminum - (6061 / 6063 / 7075 / 5052…)
  • Stainless Steel
  • Steel
  • Brass
  • Copper
  • Bronze
  • Magnesium Alloy
  • Zinc Alloy
  • Titanium alloy

ADVANTAGES & APPLICATIONS

Advantages of CNC Machining

  • Wide selection of materials, no need to compromise with raw material because parts can be CNC machined directly out of engineering plastics and metals.
  • Highly accurate and repeatable, CNC machining allows for high accuracy and excellent surface finish and/or details.
  • Fast turnaround, CNC machines can be used 24 hours a day continuously, only being turned off for maintenance.
  • Economical for short run of production parts that require wide range of operations to be performed. Scalable volumes from one to 100,000.
  • Prototypes generally large and bulky parts are economical by CNC prototyping compared to rapid prototyping processes because most of RP proprietary materials are expensive.

Prototype Machining Applications

  • Master Patterns
  • Visual Models (Concept or Exhibit)
  • Engineering Prototypes
  • Design Verification
  • Metal Prototypes
  • Production-Grade Plastic Prototypes
  • Prototyping Oversized Parts
  • Fixtures & Tools
  • Low-Volume Manufacturing
  • Market Study Models
  • Customer Evaluation

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