Fathom’s CNC Machining Service
for Your Most Demanding Applications

CNC machining is a subtractive manufacturing process. It uses computerized controls and machine tools to remove layers of material from a blank. The result is a custom-designed part.

In each case, the workpiece – the material to be machined – is secured using a jig or work-holding tool. This prevents it from moving around during the machining process.

Most CNC machining tools contain a carousel with multiple tools. The machine can change out tools as needed during the machining process, without any additional operator set-up. That saves time and money.

Three basic types of CNC machining are drilling, milling and turning:

CNC Drilling // Drill bits are used to make cylindrical holes in the workpiece. Usually, these holes are used for screws or other fasters. Normally, these holes are perpendicular to the surface of the workpiece. But specialized tools can also drill holes at an angle. Other common drilling operations include:

• Counterboring // This type of drilling creates a stepped hole so that the head of a bolt or screw is flush with the surface of the material being machined.
• Countersinking // Countersinking is like counterboring. But it creates a conical hole instead of a stepped one. That enables fasteners to sit flush with the surface of the workpiece.
• Reaming // Reaming is an operation that improves the accuracy and smoothness of pre-drilled holes. It helps the CNC machine achieve tight tolerances and high-quality finishes often required by the aerospace and automotive industries.
• Thread tapping // This operation creates internal threads within a pre-drilled hole. They enable bolts or screws to be attached to the part.

CNC Milling // This machining method uses CNC to control a rotating cutting tool. It removes material from the workpiece to create a finished part. Milling machines can cut at multiple angles and move along multiple axes:

• Three-Axis Milling // This type of milling machine can cut three surfaces of a part along its X, Y and Z axes, while the workpiece remains stationary.
• Four-Axis Milling // This type of milling machine can cut along the three linear axes (X, Y and Z). It adds an A axis, which enables the workpiece to be rotated around its X axis. This enables it to cut complex, precise shapes that aren’t possible with three-axis milling.
• Five-Axis Milling // A five-axis milling machine also enables the workpiece to be rotated along its Y-axis. It enables the machine to approach the part from all directions in a single operation. It also eliminates the need for the operator to reposition the workpiece to make more complex cuts. That saves time and money.

CNC Turning // In CNC turning, material is removed from a workpiece as it is being rotated at high speed on a lathe. It’s often used to create cylindrical parts. Common operations include straight turning, taper turning, facing, grooving and cutting:

• Straight Turning // The workpiece is rotated on a lathe as a cutting tool shapes it to a consistent diameter. It’s used to manufacture basic components like shafts, pins and rods.
• Taper Turning // As the workpiece rotates at high speed, the cutting tool gradually changes the diameter of the workpiece over its length. That gives it a tapered or conical shape.
• Facing // This operation removes material from the end of the workpiece. It ensures that the milling surface is perfectly perpendicular to the workpiece. It’s often the first step before additional machining is performed on it.
• Grooving // This is the process of cutting a recessed groove into the circumference of the workpiece. This feature is added when an O-ring needs to be integrated into the part, for example.
• Cutting or Parting // In this operation, the cutting tool slices completely through the workpiece, separating it into two sections. This enables several parts to be produced from a single piece of material.

Aerospace // Precision CNC machining is widely used in the aerospace industry, where safety is paramount and there is zero tolerance for error. Aerospace applications require precise tolerances. Weight reduction is a major priority. CNC machining is often used to produce complex parts from aluminum and titanium and their alloys

Automotive // Like the aerospace industry, the automotive sector also values parts that are precise and lightweight. Safety is also critical. CNC machining is used for both prototype part development and production. Metal can be machined for external components such as engine blocks, gearboxes, cylinders and axles. Plastic can be machined for interior components for the dashboard, gauges, and trim. The automotive industry employs strict quality standards to ensure that all parts meet their specifications. Suppliers must also follow stringent quality processes.

Consumer // CNC machining is often used to build prototypes and production parts for consumer products. Examples include appliance components, utensils, fixtures and the enclosures of some smartphones and laptop computers. They are often machined out of aluminum because of their strength and light weight.

Medical // CNC machining is commonly used to produce components for the medical industry because of its precision and accuracy. Examples include instruments and devices used in medical procedures and rehabilitation. CNC-machined parts are also used in implantable components like hips, kneecaps, screws, pins and rods. CNC machining is used throughout the product life cycle, from prototyping to production.

Technology // CNC machining is commonly used in emerging technology sectors for prototyping and small production runs. Fast turn-around and low-cost setup make CNC machining an ideal manufacturing technique for this fast-paced industry. Part redesigns are easy to accommodate because parts can be produced quickly without tooling.

Industrial // Industrial equipment takes a beating in some of the world’s most brutal environmental extremes. Machines that work in these remote places need durable parts. CNC machining is used to build parts that can withstand temperature extremes, corrosive environments and repeated impacts.

Rapid Prototyping // Parts can be CNC machined in a matter of hours, making it easy to iterate part designs and accelerate your time to market. All you need to do is generate an updated CAD drawing. We’ll convert it to the code used to drive our CNC machine tools.

Fine Details and Tight Tolerances // Because the machine tools used in this process are computer-controlled, they can produce large quantities of parts with a high degree of accuracy and repeatability.

Excellent Accuracy and Repeatability // CNC machining can be used to produce complex parts with tight tolerances. That’s important for high-performance industries like aerospace, defense and automotive.

A Wide Selection of Materials // CNC machining can be used to process many types of materials, including durable plastics and high-strength, lightweight metals. They can be finished in a variety of ways to meet specific customer requirements.

Easy to Make Design Changes // Updating the design of a part is as simple as modifying the CAD file and then generating new code to drive the CNC machine tool. That’s it – no additional tooling or preparation is needed. You can immediately start machining the new version of your part. That’s the beauty of digital manufacturing!

Produce Parts to Precise Specifications // CNC machining can produce simple parts with high precision and high accuracy, with tighter tolerances than injection molding or additive manufacturing. This makes components easier to assemble. They fit together more reliably because features align as they should. That saves time and reduces waste.

Ability to Produce Complex Shapes // CNC machining processes and cutting tools can produce many types of complex shapes with excellent accuracy and repeatability. Because they are so precise, CNC machines can produce almost any size and shape of part you can imagine.

Ideal for Prototype Parts // CNC machining is driven by the data in your part’s CAD drawing. It can produce accurate prototype parts in a matter of hours. You can also use it to iterate your way to a final design and get your parts into production faster.

Material Selection // CNC machining services can be used with a wide variety of materials, including many types of metals and alloys, plastics, phenolics and rigid foam.

Speed of Production // An automated CNC machine can run 24 hours a day, if needed, with minimal human interaction. That means it can produce your parts faster than other manufacturing methods that require more manual labor.

Reduced Waste // Unlike manual machining, which often involves a succession of trial parts until an accurate part is produced, automated CNC machines produce your parts the same way, each time. That results in less wasted material.

Affordability // A high level of automation is possible with CNC machining. That means less labor is needed to produce large quantities of parts. That makes it a surprisingly affordable manufacturing technology.

Set-Up Time // Specialized knowledge and training are required to set up and operate CNC machines. Workpieces often require custom-made fixtures and jigs to securely position and hold them during machining operations.

Design Limitations // Some organic and irregular shapes may be hard to create using CNC machining. Also, CNC machining isn’t cost-effective if you only need to produce a handful of parts.

Part Size Limitations // Larger parts may cause some limitations in cutting accuracy. That’s because their weight can place stress on the material and could cause distortion. It may also be hard for work holding fixtures to keep them securely in place.

Operator Error // CNC machining is automated. But it’s still highly dependent upon the skills and problem-solving abilities of the operator who is setting up the job. Look for a manufacturing partner that has experience making the types of parts you need.

Part Geometry Limitations // CNC machining can’t be used to create cavities within parts or conformal cooling channels. That’s because there’s no way to get a cutting tool inside of a part. Finishing internal surfaces can also be problematic.