Beyond CNC: Achieving Complexity in Precision Manufacturing

Precision CNC machining has long been seen as a leading technology for micro-manufacturing, but it no longer lays claim to offering the greatest amount of complexity at small scales. When it comes to producing intricate parts and components, new techniques like Resin Infused Powder Lithography (RIPL) can easily surpass the limitations of metal injection molding (MIM). The capacity of RIPL to produce high levels of design complexity can even match or exceed that of precision CNC machining services in a head-to-head competition.

The ultimate goal in micromanufacturing is to allow complete design freedom with geometries that other manufacturing technologies cannot achieve. Read on to learn more about how Trio Labs’ RIPL technology is achieving some of the greatest complexity in the micrometal manufacturing market.

What Are the Limitations of Using CNC Machining to Produce Micro-Scale Metal Components?

Precision CNC machining uses tools like Swiss screw machines, multi axis machining centers, and electrodes to cut and shape metal parts, creating complex parts at tiny scales. Computers control the process based on designs using modeling software. While this technology offers certain advantages, it also has some important limitations, such as the following:

• Tool size: A precision CNC machine shop’s ability to produce micro-scale parts is limited by the size of the available tools. Machining is expensive and impractical below a certain scale.
• Tool shape: Precision CNC parts may require multiple types of machine to produce certain complex parts (increasing expenses). Some features may require a turning process, while others might use vertical milling or laser cutting. Even when using the same machine, it may be necessary to change out the cutting tools for different steps of production.
• Need for precise tool and fixture alignment: The need for precision at a micro-scale means that CNC machines require careful alignment and regular maintenance to ensure accuracy. A tiny error can be disastrous to the final product. Additionally, fixture tolerances and operator error can have a huge impact on part quality, which makes it even more costly to produce quality parts consistently from CNC processes.
• Design flexibility: CNC machining can produce large numbers of precise parts, but adapting to design changes is difficult and time-consuming. A seemingly minor change to a computer model might require reconfiguring an entire CNC machine. As a result, moving from prototyping to producing an end product can require significant time and expense.

At extremely high volumes, MIM can sometimes prove to be the optimal process for the production of simple or moderately complex metal parts when compared to high-precision CNC machining. The CNC process excels most in two situations: producing large runs of simple parts or the small-scale production of highly complex parts. It’s only at the highest of volumes — and at levels of design complexity that are within MIM’s limited capabilities — that the large up-front expense of crafting molds for a MIM process becomes justified by the cost-efficiency of a quick and repeatable injection molding process.

Instead of using micro-scale tools to cut or drill metal parts into the desired shape, MIM uses molds with metal feedstocks. This allows more flexibility in terms of geometry since molds can have shapes that CNC tools might not be able to create. It can also produce parts more quickly since it does not rely on a lengthy series of machining steps. Sometimes, MIM can maintain a level of precision that is relatively close to CNC machining (depending on use case).

The need to produce a mold, however, is the most important limit on MIM’s capacity for complexity. Parts produced with MIM can only be as complex as the manufacturing process for the mold will allow.

MIM also falls short in its ability to adapt to design changes. A prototype requires one mold, and any redesigns require a completely new mold. This can create delays and add expense to the process.

What Is Possible With Resin-Infused Powder Lithography?

RIPL provides the same precision and quality as CNC machining and MIM. Where it can exceed those methods is in flexibility. With RIPL’s 3D-printing technology, moving from prototyping to final production can be as simple as updating the quantities. There is no need to reconfigure machine tools or create new molds. Additionally, many designs that are impractical or impossible with CNC or MIM become readily feasible with RIPL. Small and complex parts that are critical to highly functional medical devices can be produced easily, regardless of whether 10 parts are needed for initial testing or 1,000,000 parts are needed for production.

Move Beyond Machining and Molds. RIPL Technology Allows You to Design to the Problem, Not the Process!

Trio Labs uses cutting-edge micro-manufacturing techniques to produce medical device parts with precision, flexibility, and speed. Meet with us to request samples, receive a quote, or learn more about our capabilities. A member of our team will reach out ASAP.