Category: 3D Printing

AEROSPACE PARTS MANUFACTURING: WHEN TO CHOOSE ADDITIVE OVER TRADITIONAL MACHINING

December 1, 2025

Additive manufacturing aerospace parts can reduce weight by up to 70% compared to equivalent components made from lightweight alloys such as aluminum. This weight advantage is particularly significant in the aerospace industry, where removing just one kilogram from an aircraft can save hundreds of liters of fuel over its lifetime. Unlike traditional manufacturing methods, additive technologies enable the production of complex geometries and intricate designs that would otherwise be difficult to achieve with conventional machining processes.

While 3D printing in aerospace continues to grow as the fastest expanding industrial technique, the decision between additive and subtractive manufacturing isn’t always straightforward. CNC machining typically involves higher initial setup costs but offers cost-efficiency for high-volume production.

However, traditional methods often result in a high “buy-to-fly” ratio, indicating that a significant portion of the initial material is removed during machining, leading to increased costs and environmental implications. Additionally, specific manufacturing methods like HP MJF, FDM, SLS, and DMLS provide flexibility for custom, low-volume, and complex parts, whereas CNC machining, injection molding, and sheet metal fabrication are better suited for high-precision, high-volume production.

This article explores the critical factors aerospace professionals should consider when deciding between additive and traditional manufacturing approaches for aerospace components.

 

 

Dimensional Tolerance and Surface Finish Requirements in Aerospace

In aerospace manufacturing, precision is a fundamental requirement rather than an optional feature. The industry demands tight tolerances because even minor deviations can significantly compromise airworthiness. Consequently, understanding dimensional accuracy requirements becomes essential for selecting the appropriate manufacturing method.

AS9100 and FAA Compliance for Machined Components

The aerospace sector operates under rigorous quality standards that govern every aspect of component production. AS9100D certification, an enhancement of ISO 9001, adds specific requirements designed for aerospace manufacturing. This standard incorporates vital aspects like risk management, project management, and configuration management—making it a prerequisite for organizations supplying aerospace components. Furthermore, the Federal Aviation Administration (FAA) establishes comprehensive regulations through certification processes that ensure components meet design, operational, and safety standards. Manufacturers must maintain closed-loop quality control systems that guarantee compliance at every production stage.

 

5-Axis CNC Machining for Tight Tolerances

Five-axis CNC machining represents a significant advancement for achieving the extreme tolerances necessary in aerospace applications. This technology allows components to move in five directions simultaneously, reaching almost any angle without manual repositioning. For precision metal manufacturing, typical achievable tolerances fall within ±0.005″ to ±0.010″, depending on geometry, material, and orientation. The reduction in multiple setups leads to fewer alignment errors, resulting in parts that consistently meet strict specifications.

 

Surface Finish Standards for Flight-Critical Parts

Surface finish quality directly impacts multiple performance aspects of aerospace components, including:

  • Aerodynamic efficiency – Surface roughness influences drag, lift generation, and pressure distributions, affecting flight stability
  • Structural integrity – Even microscopic irregularities create stress concentrations that can initiate fatigue cracks under cyclic loading
  • Corrosion resistance – Rougher surfaces provide more opportunities for corrosion initiation in micro-crevices

Surface roughness is typically measured using parameters like Ra (average roughness), Rq (root mean square roughness), and Rz (average maximum height). For critical components, metrology-grade inspection verifies that surface finishes meet specifications. Additionally, specialized post-manufacturing treatments—including etching, passivation, shot peening, and polishing—can optimize surface properties while maintaining dimensional accuracy.

 

 

Material Selection: When Additive Manufacturing Excels

The selection of appropriate materials often determines whether additive manufacturing offers advantages over traditional machining methods. Modern high-performance polymers provide aerospace engineers with alternatives that excel in specific applications where weight reduction and complex geometries are essential.

 

High-Performance Thermoplastics: PEEK, ULTEM™, TORLON®

High-performance thermoplastics deliver exceptional mechanical properties while remaining up to 70% lighter than steel. Among these materials, PEEK (Polyetheretherketone) stands out with its remarkable melting point of approximately 343°C and continuous use temperature of 260°C. This semi-crystalline thermoplastic maintains its mechanical properties at elevated temperatures, making it ideal for applications requiring thermal stability. PEEK also demonstrates excellent resistance to chemicals, aircraft fuels, and steam without degradation.

ULTEM™ (Polyetherimide or PEI) offers an exceptional balance of flame retardance, low smoke emission, and toxicity compliance. With a glass transition temperature of 217°C, ULTEM™ maintains structural integrity in demanding thermal environments. Notably, ULTEM 9085 meets strict FAA regulations for flammability, making it particularly valuable for cabin interiors, ventilation systems, and food service equipment.

TORLON® (Polyamide-imide or PAI) delivers the highest tensile strength among non-filled, injection-moldable thermoplastics. With exceptional compressive strength ranging from 150 to 220 MPa, TORLON® maintains its mechanical properties at temperatures up to 260°C. Indeed, TORLON® outperforms other high-performance polymers under various extreme velocities and pressures.

 

Roboze ARGO 500 for High-Temperature Polymers

The Roboze ARGO 500 represents advanced additive manufacturing technology specifically designed for super polymers like PEEK and Carbon PEEK. With its patented beltless system, this 3D printer achieves 10μm positioning precision in XY axes and maintains consistent repeatability essential for aerospace applications. The system’s high-temperature capabilities—500°C extrusion temperature and 180°C chamber temperature—enable proper crystallization of components, eliminating the need for external thermal post-processing.

 

Biocompatibility and Weight Reduction in Aerospace Polymers

Advanced aerospace polymers offer substantial weight reduction—up to 50% compared to metal parts—directly improving fuel efficiency and lowering operational costs. This weight advantage becomes especially significant considering that removing just one kilogram from an aircraft saves thousands of fuel liters over its lifetime.

Case studies demonstrate impressive results: replacing aluminum with composite thermoplastics resulted in a 50% weight reduction and 20% cost savings for aircraft storage bin brackets. Similarly, using Carbon PA instead of metal reduced the number of parts in a centering device by 92%. Essentially, these high-performance polymers enable designers to consolidate multiple components into single, lightweight parts with complex internal geometries that would be impossible to manufacture through traditional methods.

 

 

Production Volume and Lead Time Considerations

Production volume and lead time requirements often determine the optimal manufacturing approach for aerospace components. The selection of either additive or traditional methods depends on project specifications, with each offering distinct advantages at different scales of production.

 

Rapid Prototyping with Additive Manufacturing

Additive manufacturing established its initial foothold in aerospace through rapid prototyping, enabling engineers to quickly validate designs before committing to production. This approach allows teams to transform digital models into physical prototypes without tooling requirements, accelerating the development cycle. For aerospace applications, 3D printing reduces prototype production time from weeks to mere days—or even hours—depending on component complexity. Moreover, prototyping with additive manufacturing creates opportunities for multiple design iterations, significantly reducing overall development costs.

 

Short-Run Custom Aerospace Components

For specialized aerospace components needed in limited quantities, additive manufacturing presents compelling economic advantages. The technology enables cost-effective production of short runs without the expense of tooling or molds. According to industry data, lead times for custom aerospace parts typically extend beyond 12 weeks with traditional manufacturing partners, yet additive manufacturing can deliver finished components weeks faster. Additionally, additive manufacturing demonstrates particular value for low-volume production where parts feature complex geometries or internal channels that would be impossible to produce through conventional methods.

 

High-Volume Production with CNC Machining

As production quantities increase, the economics generally shift toward traditional CNC machining. Modern multi-axis CNC systems offer unmatched consistency across thousands of identical parts. High-volume CNC machining integrates multiple functions into single units, allowing a solitary multi-axis machine to replace entire production lines. This consolidation creates substantial benefits, primarily through reduced facility requirements, decreased labor costs through automation, and lower error rates. Subsequently, high-volume aerospace manufacturers value suppliers with vertical integration capabilities that control quality across multiple manufacturing processes.

 

 

Hybrid Manufacturing for Complex Aerospace Parts

Hybrid manufacturing emerges as a strategic approach in aerospace by integrating additive and subtractive technologies into a cohesive process. This methodology capitalizes on the distinct advantages of each manufacturing technique for optimal results.

 

Additive-Subtractive Integration for Internal Channels

Complex internal geometries that remain inaccessible to conventional machining now become feasible through hybrid manufacturing. Alternating between additive and subtractive processes allows for the creation of intricate internal features by machining them as they are printed. For aerospace applications, this integration enables manufacturers to produce components with conformal cooling channels, lightweight internal structures, and complex passageways. The aerospace sector leads implementation of this technology, primarily due to demanding performance requirements.

 

Precision Polymer Components with Post-Machining

High-performance polymers often require post-machining to achieve aerospace-grade tolerances. Modern CNC systems can consistently achieve tolerances of 0.001 inches on polymer components. Appropriate tooling selection, controlled spindle speeds, and specialized cutting parameters prove essential for successful results, as polymers behave differently than metals under machining conditions. Post-processing techniques—including finishing machining, vibrating surface finishing, and drag finishing—significantly enhance surface quality.

 

Hybrid Use Cases: Brackets, Ducts, and Mounts

The integration of additive-subtractive methods excels in producing airframe brackets, structural supports, and engine components that meet rigorous aviation standards. Complex aerospace components processed through hybrid manufacturing demonstrate deviation rates under 10% compared to predicted geometry, confirming the approach’s reliability for flight-critical applications.

 

 

Conclusion

Aerospace professionals face increasingly complex choices when deciding between additive and traditional machining. Additive manufacturing offers compelling advantages in weight reduction, design freedom, and short-run efficiency, particularly when using high-performance polymers like PEEK, ULTEM™, and TORLON®. These materials enable parts that are lighter, corrosion-resistant, and capable of withstanding extreme temperatures—critical for modern aerospace applications.

However, CNC machining remains the standard for components requiring ultra-tight tolerances, AS9100D and FAA compliance, and high-volume production stability. The growing adoption of hybrid manufacturing—which combines both additive and subtractive methods—provides a best-of-both-worlds solution, especially for complex geometries and conformal cooling features.

Not sure which path is right for your part? Request a consultation with AIP Precision Machining. Our experts will guide you through design for manufacturability, material selection, and regulatory compliance for your aerospace program.

 

 

FAQs

Q1. What are the main advantages of additive manufacturing in aerospace?

Additive manufacturing in aerospace offers significant weight reduction (up to 70% compared to metal parts), enables the creation of complex geometries, and allows for rapid prototyping and production of custom, low-volume parts. These benefits contribute to improved fuel efficiency and reduced development costs.

 

Q2. When is traditional CNC machining preferred over additive manufacturing in aerospace?

CNC machining is typically preferred for high-volume production, components requiring ultra-precise tolerances, and flight-critical parts that need to meet strict AS9100D and FAA compliance standards. It offers consistent quality across large production runs and is often more cost-effective for high quantities.

 

Q3. What are some key high-performance thermoplastics used in aerospace additive manufacturing?

PEEK, ULTEM™, and TORLON® are prominent high-performance thermoplastics used in aerospace additive manufacturing. These materials offer excellent thermal stability, chemical resistance, and strength-to-weight ratios, making them suitable for demanding aerospace applications.

 

Q4. How does hybrid manufacturing benefit the aerospace industry?

Hybrid manufacturing, which combines additive and subtractive technologies, allows for the creation of complex aerospace components with internal channels, conformal cooling systems, and intricate passageways. This approach enables manufacturers to achieve optimal results in weight reduction, performance enhancement, and operational efficiency.

 

Q5. What factors should be considered when choosing between additive and traditional manufacturing for aerospace parts?

Key factors to consider include dimensional tolerance requirements, material properties, production volume, lead time, component complexity, weight reduction goals, and compliance with industry standards. The specific project requirements and desired outcomes should guide the decision between additive and traditional manufacturing methods.

Follow AIP Precision Machining on Linkedin

linkedin logo

WHY EVEN THE MOST PRECISE 3D PRINTERS FALL SHORT IN REGULATED MANUFACTURING

October 17, 2025

The aerospace industry now accounts for nearly 16% of the total revenue generated by the additive manufacturing industry. Precision 3D printers have achieved remarkable milestones, exemplified by Relativity Space launching the world’s first 3D-printed rocket in March 2023. Despite these advancements, 3D printing technology still faces significant challenges, including high costs, low printing speeds, limited part sizes, and strength issues.

While different 3D printing technologies offer varying capabilities regarding tolerances—such as MJF at ±0.3% (±0.2 mm), SLS at ±0.3% (±0.3 mm), SLA at ±0.5% (±0.2 mm), and FDM at ±0.5% (±0.5 mm)—they all struggle with fundamental limitations. This variance becomes particularly problematic in highly regulated industries like aerospace and medical device manufacturing, where even slight dimensional inaccuracies can have serious consequences.

Although processes like SLA provide fine finishes and high accuracy, materials undergo shrinkage during curing, creating internal stresses that affect dimensional accuracy. This article examines why even the most advanced 3D printing systems fall short in meeting the stringent requirements of regulated manufacturing environments, and how hybrid manufacturing approaches combining additive and subtractive methods offer a more viable solution.

 

 

Dimensional Tolerance Challenges in Precision 3D Printing

Dimensional accuracy remains a significant challenge for manufacturers relying on additive technologies, even with the most sophisticated equipment available. Resolution specifications alone fail to guarantee accurate parts, as multiple factors affect the final dimensional accuracy of printed components.

Inconsistent tolerances in FDM vs SLA vs DMLS

Each 3D printing technology offers notably different tolerance capabilities. FDM systems typically achieve tolerances of ±0.5% (lower limit: ±0.5 mm) for desktop printers and ±0.15% (lower limit: ±0.2 mm) for industrial machines. Furthermore, FDM parts frequently suffer from warping and shrinkage as layers cool at different rates, creating internal stresses that deform prints.

In contrast, SLA technology produces finer tolerances of approximately ±0.2% (lower limit: ±0.1 mm). However, the peeling process during printing can introduce dimensional inaccuracies as pulling forces cause soft prints to bend slightly.

DMLS offers tolerances of ±0.2% (lower limit: ±0.1-0.2 mm), yet the high heat involved in metal sintering often leads to shrinkage issues that must be compensated for in design.

 

3D printing tolerance for moving parts and assemblies

Achieving functional assemblies with precision 3D printers requires specific clearance considerations. For proper fit between components, manufacturers typically apply clearance gaps of 0.005″ (0.127 mm) for tight fits, 0.010″ (0.254 mm) for normal fits, and 0.020″ (0.508 mm) for loose fits.

Additionally, holes in 3D printed parts consistently print undersized due to limitations of the STL file format, which builds circles from straight-edged triangles. This characteristic necessitates accounting for these deviations when designing critical features.

 

Impact of anisotropic properties on part accuracy

Layer-by-layer fabrication inherently creates anisotropic characteristics in printed components. Mechanical testing reveals that build orientation significantly influences final properties, with parts built in upright orientation demonstrating especially poor performance.

Research confirms that raster direction substantially affects fracture behavior in FDM parts. For instance, SLA parts printed in 90° orientation exhibit greater strength but increased brittleness compared to other orientations because previously cured layers receive additional laser exposure.

This orientation-dependent performance becomes particularly problematic in regulated industries where consistent mechanical properties are essential across all dimensions. Consequently, the anisotropic nature of 3D printed parts often necessitates subsequent machining operations to achieve the uniform properties and tight tolerances required for aerospace and medical applications.

 

 

Material and Surface Limitations in Regulated Applications

Surface finish stands as a fundamental barrier to widespread adoption of additive manufacturing in regulated industries. Surface roughness, a critical quality indicator, directly impacts mechanical, physical, and tribological properties of printed components.

 

Surface roughness and porosity in aerospace-grade polymers

Internal porosity poses a significant challenge in 3D printed parts, as these invisible voids reduce component density and potentially lead to cracks, leaks, and fatigue. Recent innovations at Oak Ridge National Laboratory have demonstrated that vacuum-assisted extrusion can reduce internal porosity by up to 75% in large-scale polymer prints. This advancement is crucial given that surface irregularities disrupt boundary layer flow and accelerate the transition from laminar to turbulent flow, particularly in aerospace applications such as UAV propellers.

Moreover, surface roughness values vary dramatically between materials and printing technologies. For instance, PLA exhibits higher arithmetic mean roughness values (16.2-17.6 μm) compared to PETG (9.0-10.8 μm) in standard quality prints. These variations significantly influence functional performance, with rougher surfaces leading to enhanced aerodynamic drag and irregular airflow patterns.

 

Limitations of PEEK additive manufacturing for FDA-compliant parts

PEEK, despite its popularity in medical applications, presents substantial manufacturing challenges. Its high melting temperature, semi-crystalline structure, and significant cooling shrinkage rate increase process complexity and result in uncontrollable properties of 3D-printed parts. Indeed, the crystallization properties of PEEK are greatly affected by thermal history, requiring precise control of printing temperature, ambient temperature, and heat treatment conditions.

Another major obstacle lies in PEEK’s biological inertness, which hinders integration with bone and soft tissue—a critical requirement for medical implants. For dental applications specifically, printing high-resolution small structures (<15 mm) with fine threads proves extremely challenging, primarily because extruding PEEK through small diameter nozzles (<0.2 mm) is difficult due to the polymer’s high melt viscosity.

 

Post-processing requirements for biocompatible components

Biocompatibility certifications necessitate rigorous post-processing protocols. For instance, to achieve compliance with ISO 10993-5:2009 (cytotoxicity), ISO 10993-10:2021 (sensitization), and ISO 10993-23:2021 (irritation) standards, parts must undergo specific washing and curing processes. Typically, this involves multiple wash cycles in IPA or ethanol, followed by air drying and thermal curing.

File transfer also poses regulatory challenges, as the FDA expresses concerns about consistency across file formats. The ability to verify initial design intent throughout the manufacturing process is essential for traceability and audit purposes. Consequently, post-processing becomes a critical consideration for manufacturers seeking to produce FDA-compliant components.

 

 

Why Precision Alone Isn’t Enough for Regulated Manufacturing

Regulated manufacturing environments demand more than just dimensional accuracy from production methods. Precise tolerances serve as merely one aspect of a comprehensive quality system that must satisfy rigorous industry standards.

 

AS9100 and ISO 13485 compliance requirements

Beyond precise dimensions, AS9100 (aerospace) and ISO 13485 (medical devices) certifications require exhaustive documentation of all manufacturing processes. These standards necessitate controlled procedures, risk management protocols, and regular internal audits. For instance, ISO 13485 mandates complete product identification throughout manufacturing, thorough validation of all processes, and strict control of nonconforming products. Similarly, AS9100 requires detailed first article inspection reports documenting 100% of product characteristics.

 

Traceability and repeatability in medical device manufacturing

Medical device manufacturing mandates unbroken traceability from raw material to finished product. Every component must be traceable to its manufacturing batch, machine parameters, and operator. Nevertheless, 3D printing creates challenges in this domain as material properties can vary substantially between print jobs due to environmental factors like ambient humidity or temperature fluctuations. These variations undermine the consistency required for validated medical manufacturing processes.

 

Limitations of 3D printing in achieving validated processes

Process validation, a cornerstone requirement in regulated manufacturing, demands that manufacturers prove their processes consistently produce the same results. Unfortunately, additive manufacturing processes face inherent difficulties achieving this standard. Factors including thermal history, layer adhesion variability, and support structure removal introduce unpredictability that complicates validation efforts. Therefore, while precision 3D printers excel at creating complex geometries, they rarely satisfy the stringent validation requirements of regulated environments without substantial post-processing and secondary operations.

 

 

Hybrid Manufacturing: Bridging the Gap with CNC Machining

Hybrid manufacturing is a practical solution that combines the complex geometry capabilities of additive manufacturing with the superior surface finish and tight tolerances of precision machining. This integrated approach effectively addresses the fundamental limitations of standalone 3D printing systems.

Subtractive finishing of 3D printed parts for tight tolerances

Hybrid processes enhance dimensional accuracy dramatically—from Ra30μm in selective laser melting to Ra0.4μm after CNC finishing. Ultimately, this approach enables components to meet the micron-level tolerances required for critical applications. While precision 3D printers typically achieve tolerances around 0.1 mm, CNC machining elevates this to 0.025 mm, making hybrid manufacturing ideal for moving parts and assemblies.

 

Machined PEEK components for aerospace and medical use

PEEK stands out as an exceptional polymer for regulated applications, offering remarkable properties:

  • Maintains flexural and tensile properties at temperatures exceeding 482°F
  • Withstands over 1,500 steam autoclave cycles without significant degradation
  • Demonstrates exceptional resistance to wear, heat, and radiation

These characteristics make machined PEEK components essential for critical aerospace and medical applications where thermal, chemical, and combustion properties are paramount.

 

 

AIP’s polymer-only expertise and certified hybrid workflows

Operating under ISO 13485:2016 compliance with FDA registration status, AIP has achieved tolerance capabilities reaching ±0.002 mm. By exclusively machining plastics, they eliminate metallic cross-contamination risk—vital for biocompatible applications where material purity directly impacts patient safety.

Ready to bridge the gap between additive innovation and certified performance? Partner with AIP Precision Machining to transform your precision 3D printed parts into mission-critical components that meet the highest regulatory and engineering standards. Contact AIP’s engineering team today to discuss hybrid manufacturing solutions built for compliance, consistency, and performance.

 

 

Conclusion

Precision 3D printers have advanced rapidly, offering new possibilities in design complexity and rapid prototyping. However, when it comes to regulated manufacturing environments—where compliance, repeatability, and micron-level tolerances are non-negotiable—additive alone isn’t enough.

Across all major 3D printing technologies, issues like dimensional variability, anisotropic mechanical properties, and rough surface finishes continue to challenge part consistency. Materials such as PEEK, ideal for aerospace and medical applications, become difficult to control during additive processing due to shrinkage, crystallization, and thermal instability.

More critically, certifications like AS9100 and ISO 13485 require validated processes, traceability, and consistent outcomes—criteria that additive methods often fail to meet without secondary operations.

This is where hybrid manufacturing provides a decisive advantage. By combining the design freedom of additive with the precision, surface finish, and process control of CNC machining, manufacturers can meet both engineering and regulatory demands.

At AIP Precision Machining, we specialize in this integrated approach. With over 40 years of experience in polymer-only machining, and certified processes for high-performance plastics, we help clients turn printed parts into production-ready, regulation-compliant components.

Follow AIP Precision Machining on Linkedin

linkedin logo

MEDICAL MACHINED COMPONENTS: WHY CNC + 3D PRINTING OUTPERFORMS TRADITIONAL METHODS

August 25, 2025

Hybrid manufacturing technology reduces total production costs by 35% and shortens complex parts processing cycles by 50% compared to traditional methods. This revolutionary approach combines 3D printing (additive manufacturing) and CNC machining (subtractive manufacturing) to create superior medical machined components with unmatched precision and efficiency. The integration of these complementary technologies addresses the limitations of each individual method while maximizing their respective strengths.

When creating precision medical components, manufacturers face significant challenges with traditional production methods. CNC machining alone delivers exceptional accuracy but struggles with complex internal geometries and is more labor-intensive. On the other hand, 3D printing offers remarkable flexibility for design alterations without additional equipment setup. By combining additive and subtractive processes, medical device CNC machining achieves the best of both worlds—the design freedom of 3D printing with the precision finishing of multi-axis machining. Additionally, this hybrid approach optimizes surface quality from Ra30μm in selective laser melting to Ra0.4μm, meeting the stringent requirements for medical device implantation.

Precision machining ensures accuracy and consistency in crafting intricate medical components, allowing for the production of complex parts that meet the high standards required in the medical industry. Furthermore, advanced materials used in precision machining enhance the durability and reliability of these critical medical components. This combination of technologies represents the future of medical parts machining, offering unprecedented design possibilities while maintaining the exacting tolerances essential for patient safety.

 

How CNC and 3D Printing Work Together in Medical Machining

The synergy between additive and subtractive manufacturing creates a powerful methodology for producing precision medical components. This collaborative approach enables manufacturers to create intricate internal structures with 3D printing before achieving precise shapes and surface finishes through CNC machining.

Near-Net Shaping with Roboze ARGO 500

The Roboze ARGO 500 represents a significant advancement in medical component manufacturing. This industrial-grade 3D printer creates near-net shaped parts with 10μm positioning precision in the XY axis and handling build volumes up to 500x500x500 mm.

The system’s patented beltless technology ensures low surface roughness and CNC-grade accuracy while requiring minimal maintenance. Operating with extrusion temperatures reaching 500°C, it effectively processes high-performance polymers essential for medical applications. The system’s controlled environment maintains chamber temperatures up to 180°C, enabling stable prints with built-in annealing characteristics.

Precision Finishing with Multi-Axis CNC

Following the additive process, multi-axis CNC machining transforms the near-net shaped components into finished medical products. This subtractive technique enhances dimensional accuracy and surface quality – critical factors for medical device functionality. The process effectively takes 3D-printed parts with relatively rough surface finishes (Ra30μm) and refines them to medical-grade smoothness (Ra0.4μm). Multi-axis CNC machining particularly excels at creating precise geometries, tight tolerances, and sterilization-compatible surfaces necessary for implantable devices and surgical instruments.

Post-Processing for Sterilization-Ready Surfaces

Post-processing represents the final critical stage in hybrid medical manufacturing. Throughout this phase, components undergo precision cleaning and finishing operations specifically designed for medical-grade requirements. Proper post-processing ensures medical components can withstand rigorous sterilization protocols without degradation. The hybrid approach enables manufacturers to optimize surface characteristics for both functional performance and biocompatibility.

This integrated methodology significantly improves production efficiency, with studies showing hybrid manufacturing can reduce costs by 4-9% compared to conventional methods. Moreover, the approach creates excellent structures for osseointegration in implantable components. By combining these complementary technologies, manufacturers achieve superior results impossible with either technology alone.

 

Why Hybrid Manufacturing Outperforms Traditional Methods

Medical device manufacturers are consistently seeking manufacturing methods that offer distinct advantages over conventional approaches. The convergence of CNC machining and 3D printing in hybrid manufacturing delivers several key benefits for precision medical components.

Design Flexibility for Complex Geometry Medical Components

Hybrid manufacturing excels in creating intricate medical geometries that would be impossible or cost-prohibitive using traditional methods alone. This process allows for internal channels, lattice structures, and organic shapes that are essential in medical applications. Unlike conventional methods, hybrid approaches enable designers to build components with complex internal features first through additive manufacturing, consequently refining external surfaces with CNC machining. This dual capability is particularly valuable for customized prosthetics and implants where internal structures affect both weight and functionality.

Speed to Market with Agile Prototyping

The agile methodology inherent in hybrid manufacturing drastically reduces development cycles for medical devices. Working prototypes are produced frequently throughout development, enabling early verification through unit tests and iterative manual validation.

This approach allows manufacturers to identify and tackle critical design aspects first, hence reducing product risk. Medical device companies utilizing agile development report faster regulatory approval pathways since designs can be quickly modified based on stakeholder feedback without restarting the entire process.

Cost Efficiency in Low-Volume Production

For medical components typically produced in smaller quantities, hybrid manufacturing presents compelling financial advantages:

  • Elimination of expensive tooling costs required in traditional manufacturing
  • Reduced inventory carrying costs through on-demand production
  • Lower overall production costs—between 4-9% compared to conventional methods

Enhanced Mechanical Properties in Super Polymers

Super polymers processed through hybrid manufacturing maintain exceptional performance characteristics even in extreme conditions. Materials like PEEK demonstrate remarkable thermal versatility, functioning across wide temperature ranges while retaining structural stability. In fact, when properly processed through hybrid methods, these components can achieve tensile strength approximately 71.6% of injection-molded equivalents. This combination of strength, biocompatibility, and radiolucence makes hybrid-manufactured components ideal for applications where both mechanical properties and patient monitoring are crucial.

 

Material Considerations for Medical Hybrid Manufacturing

Selecting appropriate materials remains a critical factor in successful hybrid manufacturing for medical applications. The unique combination of additive and subtractive processes demands materials that maintain integrity throughout both production stages.

PEEK and PPSU: Biocompatibility and Sterilization Compatibility

PEEK (Polyetheretherketone) stands out as an exceptional polymer for medical applications, offering biocompatibility for implants with ISO 10993 certification and a modulus similar to human cortical bone. This material demonstrates remarkable sterilization resistance, withstanding over 1,500 steam autoclave cycles without significant property degradation. PPSU (Polyphenylsulfone) surpasses other sulfone-based polymers with impact resistance measuring up to 13 ft-lbs/in. Radel PPSU maintains its properties after 1,000 autoclave cycles, making it ideal for reusable medical instruments.

Torlon Medical Applications for High-Load Environments

Torlon PAI (Polyamideimide) delivers unmatched performance among melt-processable thermoplastics. Its compressive strength doubles that of PEEK when unfilled. Torlon’s exceptional wear resistance ensures longevity in peristaltic pump rollers and prosthetic bushings. Medical grade Torlon offers high modulus, radiolucency, sterilization compatibility, and superior dimensional stability across its entire service temperature range.

Machining Radiolucent and Implantable Polymers

Implantable medical devices require biocompatible materials that serve functions for 30+ days. PEEK’s radiolucent properties allow unobstructed imaging through MRI, X-rays, and CT scans. Carbon fiber reinforcement can boost structural strength for load-bearing applications. Additionally, barium sulfate additives increase radiopacity for surgical monitoring without affecting biocompatibility.

Contamination Control in Polymer-Only Machining Environments

Dedicated polymer-only machining environments essentially eliminate metallic cross-contamination risks. Medical components require strict adherence to ISO 13485 and FDA standards for quality management. Ensuring sterilization begins with selecting manufacturers committed to preventing contamination at even sub-molecular levels.

 

AIP Precision Machining: Certified Excellence in Medical Manufacturing

For three decades, AIP Precision Machining has established itself as a leader in producing advanced medical machined components. Their commitment to quality extends throughout their entire manufacturing process, from initial concept through final delivery.

ISO 13485 and FDA-Registered Facility Standards

AIP operates under ISO 13485:2016 compliance and maintains FDA registration status, having successfully passed audits from the most demanding orthopedic and medical device OEMs. These certifications reflect their adherence to the international standard specifically designed for medical device quality management systems. This regulatory framework ensures consistent quality, proper documentation, and risk-based decision making throughout the manufacturing process.

±0.002 mm Tolerance Capabilities

Precision defines AIP’s manufacturing approach, with tolerance capabilities reaching ±0.002 mm. This exceptional accuracy allows their team to machine custom medical components within ten-thousandths of an inch or less. Such precision is crucial for components like surgical instruments, implantable prototypes, and diagnostic equipment where micron-level tolerances are mandatory rather than optional.

Dedicated Polymer-Only Machining Environment

AIP exclusively machines plastics, thereby eliminating the risk of metallic cross-contamination. This dedicated approach proves especially valuable for biocompatible applications where material purity directly impacts patient safety. Their specialized environment maintains strict hygienic procedures throughout the manufacturing process.

Roboze ARGO 500 for High-Performance Additive Manufacturing

The integration of Roboze ARGO 500 technology into AIP’s capabilities elevates their hybrid manufacturing potential. This system delivers 10μm positioning precision in XY axis, creating large-format parts with industrial-grade accuracy and exceptional dimensional repeatability. The system’s beltless technology ensures CNC-grade precision throughout the additive process.

Schedule a Design-for-Manufacturing Consultation – Partner with our engineering team at AIP to optimize your part for both additive and CNC production.

 

Conclusion

The future of medical component manufacturing clearly belongs to hybrid manufacturing technologies. This integrated approach effectively addresses the limitations of traditional methods while delivering unprecedented precision and efficiency. Companies accordingly benefit from 35% lower production costs and 50% shorter processing cycles, particularly essential for time-sensitive medical innovations.

Medical devices demand exacting standards that hybrid manufacturing consistently meets through its complementary processes. CNC machining brings ±0.002 mm tolerance capabilities, while additive technologies create previously impossible internal geometries. Together, these technologies transform surface quality from Ra30μm to medical-grade Ra0.4μm finishes.

Super polymers processed through this hybrid methodology maintain exceptional performance characteristics across challenging medical environments. PEEK demonstrates remarkable biocompatibility with ISO 10993 certification, while PPSU withstands 1,000 autoclave cycles without degradation. Torlon PAI similarly excels with compressive strength doubling that of PEEK, making these materials ideal for demanding medical applications.

AIP Precision Machining stands at the forefront of this manufacturing revolution with three decades of specialized experience. Their ISO 13485:2016 compliance and FDA registration guarantee adherence to stringent quality management systems. The dedicated polymer-only environment eliminates cross-contamination risks, thus ensuring patient safety remains paramount throughout production.

The combination of Roboze ARGO 500 technology and multi-axis CNC capabilities provides medical device manufacturers unprecedented design freedom. This approach especially benefits complex geometries, customized implants, and specialized surgical instruments that traditional manufacturing methods struggle to produce efficiently.

Medical component development teams should therefore consider partnering with AIP for their next project. Their expertise spans the entire production process from initial design consultation through final quality verification. Schedule a design-for-manufacturing consultation today to discover how hybrid manufacturing technologies can optimize your medical components for both performance and production efficiency.

 

Key Takeaways

Hybrid manufacturing combining CNC machining and 3D printing is revolutionizing medical component production, delivering superior results that neither technology can achieve alone.

  • Hybrid manufacturing reduces costs by 35% and shortens processing cycles by 50% compared to traditional methods while achieving medical-grade surface finishes.
  • Complex internal geometries become possible through 3D printing’s design freedom, followed by CNC machining’s precision finishing for tight tolerances.
  • Super polymers like PEEK and PPSU maintain exceptional biocompatibility and can withstand over 1,000 sterilization cycles without degradation.
  • Dedicated polymer-only machining environments eliminate metallic contamination risks while maintaining ISO 13485 and FDA compliance standards.
  • Tolerance capabilities reach ±0.002 mm precision with surface quality improvements from Ra30μm to Ra0.4μm for implantable medical devices.

This manufacturing approach particularly excels in low-volume medical device production, enabling rapid prototyping and customized implants while meeting the stringent quality requirements essential for patient safety and regulatory approval.

 

FAQs

Q1. How does hybrid manufacturing combine CNC machining and 3D printing for medical components?

Hybrid manufacturing integrates 3D printing for creating complex internal geometries and near-net shapes, followed by CNC machining for precision finishing. This combination allows for intricate designs with tight tolerances and medical-grade surface finishes, achieving results impossible with either technology alone.

Q2. What are the key advantages of hybrid manufacturing over traditional methods for medical devices?

Hybrid manufacturing offers several benefits: 35% lower production costs, 50% shorter processing cycles, greater design flexibility for complex geometries, faster prototyping, and cost-efficiency in low-volume production. It also allows for enhanced mechanical properties in super polymers used for medical applications.

Q3. Which materials are commonly used in hybrid manufacturing for medical components?

Common materials include PEEK and PPSU for their biocompatibility and sterilization resistance, Torlon PAI for high-load environments, and various radiolucent and implantable polymers. These materials maintain their integrity throughout both additive and subtractive manufacturing processes.

Q4. How does hybrid manufacturing improve surface quality for medical components?

Hybrid manufacturing can significantly improve surface quality, transforming 3D-printed parts with relatively rough surface finishes (Ra30μm) to medical-grade smoothness (Ra0.4μm) through precision CNC machining. This level of surface refinement is crucial for implantable devices and surgical instruments.

Q5. What certifications are important for manufacturers using hybrid technologies for medical components?

Manufacturers should adhere to ISO 13485:2016 standards for medical device quality management systems and maintain FDA registration. These certifications ensure consistent quality, proper documentation, and risk-based decision making throughout the manufacturing process, which is crucial for medical device production.

Follow AIP Precision Machining on Linkedin

linkedin logo

HOW TO ACHIEVE PRECISION 3D PRINTING WITH HIGH-PERFORMANCE POLYMERS

January 23, 2025

Precision 3D printing with high-performance polymers represents a significant advancement in additive manufacturing technology. Modern aerospace components and medical devices demand exceptional accuracy, superior mechanical properties, and consistent material performance. These critical applications require specialized materials like PEEK and advanced manufacturing processes that meet strict industry standards while delivering reliable results.

The successful implementation of high-precision 3D printing depends on several key technical factors. Material selection, hardware optimization, and parameter control play crucial roles in achieving optimal results. This article examines essential considerations for polymer selection, hardware requirements, and slicing parameters that enable manufacturers to produce complex geometries with superior accuracy. Readers will learn practical approaches to enhance print quality, reduce costs, and accelerate time-to-market through effective part consolidation and process optimization.

 

Selecting the Right High-Performance Polymer for Your Application

Selecting appropriate high-performance polymers (HPPs) for precision 3D printing requires careful consideration of multiple factors that directly impact part performance and manufacturing success. Engineers must evaluate various material characteristics to ensure optimal results in their specific applications.

Evaluating mechanical properties and heat resistance

High-performance polymers demonstrate exceptional mechanical properties crucial for demanding applications. PEEK (polyetheretherketone) stands out with its continuous use temperature of 260°C and superior strength-to-weight ratio. It also maintains excellent mechanical properties even under elevated temperatures, making it ideal for aerospace and automotive applications.

For applications requiring extreme temperature resistance, materials like ULTEM 1010 offer a heat deflection temperature of 216°C with outstanding dimensional stability. The mechanical properties of these materials remain stable across a wide temperature range, ensuring consistent performance in challenging environments.

Considering chemical resistance and durability

Chemical resistance ratings for high-performance polymers typically follow a four-tier system:

  • Level 1: Excellent resistance – suitable for prolonged exposure
  • Level 2: Good resistance – appropriate for short-term exposure
  • Level 3: Limited resistance – potential degradation during short exposure
  • Level 4: Poor resistance – rapid material degradation

PEEK demonstrates remarkable chemical resistance, particularly against jet fuel, hydraulic fluids, and industrial cleaners. Its semi-crystalline structure provides excellent creep and fatigue resistance, often surpassing traditional metals in long-term durability tests.

 

Matching polymer characteristics to specific industry needs

Different industries require specific material characteristics for their unique applications. In aerospace manufacturing, materials must combine lightweight properties with exceptional strength and heat resistance. Medical applications demand biocompatible materials that can withstand sterilization processes while maintaining dimensional accuracy.

The automotive sector benefits from materials offering:

  • High impact resistance and durability
  • Excellent chemical resistance to fuels and lubricants
  • Superior thermal stability
  • Enhanced wear resistance for dynamic applications

Cost-benefit analysis of different high-performance polymers

While high-performance polymers typically command premium prices compared to standard engineering plastics, their advanced properties often justify the investment through:

  1. Extended component lifespan
  2. Reduced maintenance requirements
  3. Enhanced performance in extreme conditions
  4. Decreased system downtime
  5. Lower overall lifecycle costs

Material selection should consider both immediate manufacturing costs and long-term performance benefits. For instance, PEEK-based carbon fiber composites, despite higher initial costs, offer specific strength several times that of metals, potentially reducing overall system weight and operating costs.

The adoption of high-performance polymers in additive manufacturing continues to expand as manufacturers recognize their advantages in producing complex, lightweight components with superior mechanical properties. These materials enable the production of parts that maintain structural integrity under extreme conditions while offering design flexibility unattainable with traditional manufacturing methods.

 

Optimizing 3D Printer Hardware for High-Performance Polymers

Successful implementation of high-performance polymer printing requires precise hardware optimization to achieve superior part quality and consistency. Engineers must carefully consider each component’s specifications to ensure optimal performance in demanding applications.

Choosing the appropriate nozzle and extruder

The selection of proper nozzle and extruder combinations significantly impacts print quality when working with high-performance polymers. Hardened steel nozzles with a hardness scale of 6-8 mohs provide superior wear resistance compared to standard brass options, making them ideal for abrasive materials. For optimal performance, manufacturers should consider the following specifications:

Nozzle Type Temperature Range Recommended Materials
Hardened Steel Up to 500°C PEEK, ULTEM, Carbon-reinforced
Ruby Tip Up to 500°C Highly abrasive materials
CHT (Triple-path) Up to 500°C High-flow applications

Modern high-flow extruders can achieve pushing forces up to 12 kilos, enabling consistent material flow even with highly viscous polymers. The implementation of dual-drive systems with specialized gear designs ensures reliable feeding of challenging materials.

Upgrading to a high-temperature print chamber

Temperature-controlled chambers are essential for achieving optimal layer adhesion and preventing warpage in high-performance polymers. Active chamber heating systems capable of maintaining temperatures up to 90°C provide several advantages:

  • Improved layer bonding through controlled cooling rates
  • Enhanced stress relief during printing
  • Reduced warpage through uniform temperature distribution
  • Better crystallization control for semi-crystalline polymers

Implementing advanced cooling systems

Precise thermal management plays a crucial role in achieving dimensional accuracy and structural integrity. Advanced cooling systems must maintain optimal temperature gradients throughout the printing process. The implementation of independent motor drivers and specialized cooling solutions enables precise control over material crystallization and layer adhesion.

Modern cooling systems incorporate:

  1. Multi-zone temperature control
  2. Independent fan speed regulation
  3. Targeted cooling paths
  4. Advanced thermal monitoring

Selecting compatible build plates and adhesion solutions

Build plate selection significantly impacts first-layer adhesion and overall print success. Nano-polymer adhesive solutions specifically designed for high-temperature applications can withstand pulling forces exceeding 20,000 PSI. These advanced adhesives maintain effectiveness across multiple surfaces, including:

  • Borosilicate glass
  • Carbon fiber composites
  • PEI-coated surfaces
  • Ceramic glass plates

For optimal results with high-performance polymers, manufacturers should implement self-leveling build plates capable of maintaining temperatures up to 200°C. These systems provide consistent first-layer adhesion while accommodating the significant thermal expansion characteristics of advanced polymers.

The integration of flexible build plates with specialized coatings facilitates easier part removal while maintaining dimensional accuracy. When working with materials like PEEK or ULTEM, rapid part removal at elevated temperatures prevents potential thermal stress-induced damage to both the printed component and build surface.

Advanced hardware configurations enable manufacturers to achieve precise control over the entire printing process, from initial material deposition through final part completion. This level of control ensures consistent quality and reliability in critical applications across aerospace, medical, and industrial sectors.

 

Mastering Slicing and Print Parameters for Precision Results

Achieving optimal results in precision 3D printing requires mastery of slicing parameters and print settings. Engineers must carefully balance multiple variables to ensure consistent quality and dimensional accuracy in critical applications.

Fine-tuning layer height and extrusion width

Layer height configuration directly influences both print quality and mechanical properties. Optimal layer height typically ranges between 0.05mm and 0.4mm, depending on the nozzle diameter. For high-performance polymers, manufacturers should consider the following relationships:

Layer Height (mm) Surface Quality Print Speed Mechanical Strength
0.05 – 0.1 Excellent Slow High
0.15 – 0.2 Good Moderate Moderate
0.25 – 0.4 Fair Fast Variable

 

Extrusion width settings significantly impact part strength and dimensional accuracy. The optimal extrusion width typically ranges from 100% to 120% of the nozzle diameter. Engineers should maintain consistent pressure inside the nozzle to achieve uniform material deposition and enhanced layer bonding.

Optimizing print speed and cooling rates

Temperature control and print speed optimization are crucial for achieving superior results with high-performance polymers. The relationship between these parameters affects both mechanical properties and surface finish. Key considerations include:

  • Material crystallization rates
  • Layer adhesion requirements
  • Thermal gradient control
  • Dimensional stability

Print speed optimization requires careful consideration of material properties and geometric complexity. For high-performance polymers, manufacturers typically achieve optimal results with speeds ranging from 30mm/s to 60mm/s for outer perimeters and up to 150mm/s for infill sections.

 

Adjusting infill patterns and density for strength and accuracy

Infill configuration plays a critical role in determining part strength and performance characteristics. Advanced infill patterns offer varying benefits:

  1. Gyroid Pattern
    • Superior strength distribution
    • Enhanced heat dissipation
    • Improved layer bonding
  2. Triangular Pattern
    • Maximum vertical load capacity
    • Enhanced structural stability
    • Optimal for aerospace applications

Density settings typically range from 20% for prototype components to 50% or higher for functional parts requiring maximum strength. Engineers should consider that increasing infill density beyond 75% yields diminishing returns in strength improvement while significantly increasing material consumption and print time.

 

Implementing advanced slicing techniques for complex geometries

Modern slicing software enables sophisticated approaches for handling complex geometries and achieving superior surface quality. Non-planar slicing techniques allow for optimized tool paths that follow part contours, resulting in enhanced surface finish and improved mechanical properties.

Advanced slicing parameters for complex geometries include:

Parameter Function Impact
Adaptive Layers Varies layer height based on geometry Enhanced detail preservation
Variable Width Adjusts extrusion width dynamically Improved dimensional accuracy
Gradient Infill Modifies density based on stress requirements Optimized strength-to-weight ratio

 

For critical aerospace and medical device applications, manufacturers should implement specialized slicing strategies that account for:

  • Thermal stress distribution
  • Support structure optimization
  • Surface quality requirements
  • Dimensional tolerance specifications

The implementation of advanced cooling control systems enables precise management of material crystallization rates. Forced-air cooling with controllable speed directly influences both dimensional quality and mechanical strength. Higher airflow velocities typically improve dimensional accuracy but may decrease mechanical properties, requiring careful optimization based on specific application requirements.

Engineers must consider the relationship between layer bonding and void content, as these factors significantly influence part strength. The surrounding temperature and convection coefficient inside the build chamber strongly affect the cooling temperature profile, mesostructure, and bond strength of printed components.

For optimal results with high-performance polymers, manufacturers should implement comprehensive parameter optimization strategies that account for:

  1. Material-specific crystallization behavior
  2. Thermal mass considerations
  3. Build chamber environmental control
  4. Layer adhesion requirements
  5. Surface quality specifications

The successful implementation of these advanced slicing and parameter control strategies enables manufacturers to achieve exceptional quality and consistency in critical applications. Through careful optimization of these parameters, engineers can maximize both mechanical properties and dimensional accuracy while maintaining efficient production cycles.

 

Conclusion

Precision 3D printing with high-performance polymers demands mastery across multiple technical domains. Material selection establishes the foundation through specific mechanical properties, chemical resistance, and thermal characteristics that match application requirements. Hardware configurations, including specialized nozzles, temperature-controlled chambers, and advanced cooling systems, create the necessary manufacturing environment. Parameter optimization through precise control of layer heights, print speeds, and infill patterns ensures consistent quality and dimensional accuracy across critical applications.

Manufacturing success relies on careful integration of these technical elements while maintaining strict quality standards throughout production. Companies must evaluate their specific requirements against material capabilities, equipment specifications, and process parameters to achieve optimal results. Accelerate your project with AIP’s precision 3D printing for rapid prototyping – our expertise in high-performance polymers and advanced manufacturing processes helps speed up product development from concept to prototype. Professional guidance through these technical considerations ensures manufacturers maximize the benefits of precision 3D printing while meeting demanding industry requirements.

Follow AIP Precision Machining on Linkedin

linkedin logo

Aerospace Parts Manufacturing Landscape: Innovations And Challenges

April 29, 2024

 

In the aerospace engineering market, precision parts manufacturing is a critical discipline that significantly influences the functionality and safety of aviation technologies.

From the early 20th century’s rudimentary constructions to today’s advanced aerospace assemblies, the sector has seen a pivotal shift towards the utilization of high-performance materials and complex manufacturing techniques.

This evolution is set to propel the industry from a valuation of $910 billion in 2023 to an estimated $1.297 trillion by 2033, driven by both burgeoning aircraft production and the perpetual need for meticulously crafted replacement components.

Contemporary aerospace manufacturing is defined by stringent precision requirements, with materials selected for their superior strength-to-weight ratios essential in components demanding both lightness and durability.

Advanced manufacturing processes including Computer Numerical Control (CNC) machining, flow forming, and rotary forging are employed to ensure components conform to exacting aerospace standards.

The integration of polymer composites and advanced materials such as carbon-fiber-reinforced polymers (CFRP) is instrumental in reducing aircraft mass while sustaining structural robustness. This adoption of innovative materials and precision-focused manufacturing techniques underlines the industry’s commitment to advancing aviation technology through rigorous engineering practices.

This enhanced focus on precision and technological sophistication underscores the modern aerospace manufacturing landscape, emphasizing the industry’s dedication to pushing the boundaries of aviation through precision engineering and state-of-the-art material science.

 

Advanced Materials and Manufacturing Processes

In the aerospace parts manufacturing sector, the selection and processing of materials are driven by the industry’s unyielding pursuit of advancements in strength, weight reduction, and resistance to extreme conditions.

 

High-Performance Alloys:

  • Aerospace-grade aluminum and titanium are valued for their exceptional strength-to-weight ratios, vital for components requiring both light weight and durability.
  • Aluminum is preferred for its combination of lightness, strength, corrosion resistance, and abundance, making it a cornerstone in aerospace manufacturing.
  • Titanium and its alloys, known for their superior strength-to-weight ratio and performance in extreme environments, are extensively utilized in critical aerospace applications.

 

Polymer Composites and Advanced Materials:

  • Polymer composites, including carbon-fiber-reinforced-polymers (CFRP), offer a blend of lightweight characteristics and structural integrity, crucial for reducing aircraft and spacecraft weight while maintaining performance.
  • Graphene, a novel carbon-based material, is under exploration for its potential in creating high-capacity, lightweight batteries, embodying the aerospace industry’s forward-looking approach to materials innovation.

 

Manufacturing Processes and Technological Advancements:

  • Techniques such as powder bed fusion and direct energy deposition stand at the forefront of material processing, ensuring components meet the aerospace industry’s stringent standards.
  • The development of machinable alloys and advanced structural technologies like flow forming and rotary forging exemplifies the industry’s commitment to efficiency and precision in manufacturing processes.

 

 

Advanced Composites in Aerospace

Advanced composites, characterized by their hybrid nature, combine two or more distinct materials to enhance overall properties, making them indispensable in modern aerospace parts manufacturing. One prominent example is Carbon Fiber Reinforced Polymer (CFRP), widely utilized for its exceptional strength-to-weight ratio, durability, and resistance to corrosion.

Notably, Boeing, a leader in aerospace innovation, has filed a significant number of patents related to CFRP, underscoring its commitment to advancing composite technology.

These materials are pivotal in the production of critical aircraft components such as fuselages, wings, and tail sections. Their application results in substantial weight reduction, which in turn contributes to enhanced fuel efficiency—a key advantage seen in models like Boeing’s 787 Dreamliner, which boasts a 20% improvement in fuel economy over its predecessors.

However, the high cost of production, driven by labor-intensive processes and the need for specialized equipment, has historically limited their widespread adoption.

Despite these challenges, ongoing advancements in precision manufacturing techniques are enhancing the utility and application of these materials.

AIP Precision Machining stands at the forefront, innovating strategies that ensure the highest quality and precision standards while extending the use of advanced composites in aerospace and related industries.

These efforts not only optimize the functionality of advanced composites but also secure their essential role in the evolution of aerospace engineering, meeting the industry’s stringent demands for accuracy and reliability.

 

 

Smart Materials: Shaping the Future of Aerospace

The utilization of smart materials is transforming aerospace parts manufacturing by enabling aircraft components to intelligently adapt and respond to dynamic environmental conditions. Shape Memory Alloys (SMAs) and Piezoelectric Materials are at the forefront of this revolution, significantly boosting the performance and operational efficiency of aerospace systems.

Precision in the application of these materials is critical, as the slightest deviations can impact the functionality and safety of the aerospace components.

AIP Precision Machining is uniquely equipped to meet these challenges. With cutting-edge technology and extensive expertise in precision engineering, AIP ensures that the transformative potential of smart materials is fully realized in aerospace applications, setting new standards in performance and reliability.

 

Shape Memory Alloys and Piezoelectric Materials

  1. Shape Memory Alloys (SMAs): SMAs are utilized in critical aerospace applications such as wing flaps and landing gear. They contribute significantly to aerodynamics and fuel efficiency by reverting to a pre-determined shape in response to temperature changes.
  2. Piezoelectric Materials: These materials are essential in the development of sensors and actuators for aircraft. By generating an electric charge in response to mechanical stress, they help monitor and control the structural health of the aircraft, particularly in the wings and fuselage.

 

Innovations in Morphing Wings and Self-Healing Materials

  • Morphing Wings: Smart materials facilitate the development of morphing wings, which adjust their shape during flight to optimize performance. This adaptability is crucial for reducing drag and improving fuel efficiency.
  • Self-Healing Materials: Capable of autonomously repairing minor damages and cracks, these materials extend the lifespan of aerospace components, thereby reducing maintenance costs and enhancing safety.

 

 

Advanced Sensing and Thermal Control

Smart materials are integral to the development of sophisticated sensing and monitoring systems that detect environmental changes such as temperature and stress, essential for real-time aerospace decision-making.

Additionally, materials with adaptive thermal control properties play a crucial role in managing heat distribution, protecting critical components, and ensuring the optimal performance of onboard electronic systems. The deployment of these advanced materials in aerospace manufacturing not only requires high precision but also compliance with rigorous industry standards such as AS 9100 certification.

This standard is critical as it ensures quality assurance and reliability in all aspects of aerospace manufacturing, from material selection to final product testing. AIP Precision Machining, with its AS 9100 certification, exemplifies adherence to these high standards, guaranteeing that every component manufactured meets the strict requirements for aerospace applications. This commitment to certified quality enhances the potential of smart materials to advance aerospace technology, focusing on sustainability and operational efficiency.

 

 

The Impact of Nanocomposites

Nanocomposites are emerging as a transformative force in aerospace parts manufacturing, blending nanoparticles with traditional composite materials to achieve superior properties. These materials are engineered by incorporating nanoscale fillers into resins or polymers, resulting in composites that are lightweight yet extremely strong and durable. The integration of nanotechnology within composites leads to enhancements in mechanical strength, thermal stability, and electrical conductivity, which are critical for aerospace applications where performance and reliability are paramount.

 

Enhanced Mechanical Properties

Nanocomposites significantly improve the mechanical properties of aerospace materials, including tensile strength, stiffness, and impact resistance.

For instance, the addition of nano-sized carbon fibers or silica particles to polymer matrices has shown to increase the load-bearing capacity of aircraft components while maintaining a low weight. This enhancement is crucial in the design of more efficient and higher-performing aircraft structures that can withstand the demanding conditions of aerospace environments.

 

Thermal and Electrical Conductivity Improvements

By integrating nanomaterials like graphene or metal oxides, nanocomposites gain improved thermal and electrical conductivities. This is particularly advantageous for aerospace parts that require efficient heat dissipation or electrical grounding.

Enhanced thermal stability ensures that components can perform reliably under the extreme temperature variations experienced during flight and re-entry phases, while improved electrical properties are essential for protecting sensitive electronic equipment from static and electromagnetic interference.

These advancements in nanocomposite technology not only drive the performance and efficiency of aerospace systems but also contribute to the overall safety and longevity of aircraft. The strategic incorporation of nanotechnology in composite materials is setting new benchmarks in aerospace engineering, aligning with the industry’s goals of innovation and sustainability.

 

 

The Promise of Additive Manufacturing

Additive manufacturing, often synonymous with 3D printing, is transforming aerospace parts manufacturing by enabling the creation of complex, lightweight designs that traditional methods cannot achieve. This innovative approach allows for the production of parts with intricate geometries such as lattice structures and conformal cooling channels, which significantly enhance the performance and efficiency of aerospace components.

 

 

Additive Manufacturing (3D Printing) in Aerospace

In the aerospace parts manufacturing sector, additive manufacturing (AM), or 3D printing, has emerged as a revolutionary technology, offering unprecedented flexibility and efficiency. The adoption of AM across various applications illustrates its transformative impact:

 

Innovative Applications and Prototyping:

  • Nano Dimension utilizes AME and DragonFly IV technology for aerospace and defense, showcasing advanced 3D printing capabilities.
  • Masten Space Systems leverage 3D printing for rapid prototyping of functional rocket components, including complex parts like the 25,000-pound thrust broadsword engine.
  • Lufthansa Technik demonstrate the cost and time efficiency of 3D printing in aerospace tooling and part production, such as the extrusion nozzle for self-luminous escape route markings.

 

Enhanced Manufacturing Efficiency:

  • The Integrated Manufacturing Group at AMRC illustrates time savings in high-tolerance drilling and machining through 3D printed masking jigs.
  • NASA and educational institutions like the United States Naval Academy employ 3D printing for space testing and educational purposes, respectively, highlighting the technology’s broad applicability and potential for innovation.

 

Design and Material Innovations:

  • Aerospace companies are increasingly favoring 3D printing for its ability to produce and evaluate multiple design variations quickly, including the production of high-pressure turbine discs from challenging materials like nickel-based superalloys.
  • The technology enables the reduction of aircraft mass by experimenting with lightweight, high-strength materials and consolidating multiple parts into a single, more efficient component.

These examples underscore the pivotal role of additive manufacturing in propelling the aerospace parts manufacturing industry forward, driven by its capacity for innovation, efficiency, and material optimization.

 

 

The Role of Digital Twin Technology

In the aerospace parts manufacturing arena, digital twin technology has become an indispensible tool, enhancing the precision and reliability of complex systems. This technology offers a comprehensive virtual representation of physical components, including aircraft and satellites, allowing for meticulous testing and validation in simulated environments.

 

Key aspects include:

  • Functionality Across Environments: Digital twins ensure the reliable operation of electronic systems, critical in varying operational conditions.
  • Prototyping and Deployment: By mimicking both hardware and software functionalities, digital twins facilitate early modeling and analysis, significantly reducing costs and accelerating deployment rates.
  • Real-World Testing: Essential for aerospace and government sectors, this technology enables rigorous testing, validation, and verification processes, enhancing hardware and software compatibility in actual conditions.

Moreover, digital twin technology stands at the forefront of Industry 4.0, integrating data analytics and machine learning to create dynamic, evolving models.

 

Notable applications include:

  • Rolls-Royce’s UltraFan Engine: Utilizing digital twins for creating precise virtual replicas, enabling virtual testing as if the engine were operating in real-world conditions.
  • Operational Performance Optimization: Through advanced diagnostics and comprehensive lifecycle management, digital twins offer unparalleled forecasting capabilities, leading to optimized fleet management and superior overall operational efficiency.

This integration of digital twin technology within aerospace manufacturing underscores a significant shift towards smarter, more efficient production methodologies. By harnessing the power of virtual simulations, aerospace engineers can predict maintenance needs, improve equipment development, and streamline the validation of complex systems, marking a pivotal advancement in aerospace parts manufacturing.

 

 

Future Trends in Aerospace Parts Manufacturing

Several key trends are poised to redefine the aerospace parts manufacturing landscape, driven by technological advancements and the drive for sustainability:

 

Technological Innovations:

  • Autonomous Flight Systems are on the brink of revolutionizing air travel, with single-pilot commercial aircraft and the potential for pilotless passenger flights, enhancing efficiency and safety.
  • Artificial Intelligence (AI) and the Internet of Things (IoT) are streamlining operations from material analysis to predictive maintenance, ensuring a smarter, more responsive supply chain.
  • Additive Manufacturing continues to advance, with GE Additive leading in Direct Metal Laser Melting (DMLM) and Electron Beam Melting (EBM) technologies, enabling the production of complex aerospace components with unprecedented precision.

 

Sustainability and Efficiency:

  • The industry’s commitment to sustainability is evident in the exploration of alternative fuels and the adoption of electric propulsion systems, aiming to reduce carbon footprints and operational costs.
  • Robotics and Automation are increasingly embraced to enhance production efficiency, while sustainable manufacturing practices focus on cleaner production, waste reduction, and recycling.

 

Market Dynamics:

  • With an anticipated growth to $1.51 trillion by 2032, the aerospace parts manufacturing market is buoyed by the demand for fuel-efficient, lighter aircraft and advanced aeronautical equipment.
  • Challenges such as supply chain disruptions and material price volatility are being addressed through diversification and digital transformation, ensuring resilience and security.

 

These trends underscore a future where aerospace parts manufacturing is more efficient, sustainable, and technologically advanced, promising an exciting era of innovation and growth.

 

 

In Conclusion

The aerospace parts manufacturing industry is at the forefront of technological advancement, integrating revolutionary materials, precision engineering techniques, and digital innovations.

As the industry advances, it is poised for significant growth, setting new standards in aerospace capabilities and efficiency.

AIP Precision Machining is at the heart of these developments, bolstered by our AS 9100 and ISO 13485:2016 certifications. The AS 9100 certification is crucial, ensuring that our aerospace manufacturing processes and products consistently meet the highest safety and quality standards. This certification is vital for maintaining the rigorous demands of aerospace component precision and reliability, which are vital in the highly regulated aerospace sector.

Additionally, our ISO 13485:2016 certification, while primarily recognized in the medical devices industry, complements our aerospace capabilities by enforcing stringent quality management practices. This dual certification allows us to handle complex aerospace projects that may involve advanced materials and technologies, providing a cross-industry perspective that enhances innovation and meticulous attention to detail.

These certifications affirm AIP Precision Machining’s commitment to excellence and our capability to meet diverse industry requirements, reinforcing our position as a leader in aerospace parts manufacturing. They underscore our ability to deliver components that not only meet but exceed the evolving expectations of the aerospace industry.

We encourage aerospace entities seeking a manufacturing partner that exemplifies integrity, precision, and advanced technological compliance to consider AIP Precision Machining. Let us collaborate to drive the future of aerospace, where cutting-edge technology and rigorous standards propel us towards unparalleled achievements in aviation excellence.

Contact us at:

Phone: +1 386-274-5335

Website: www.aipprecision.com

 

 

FAQs

What are the main obstacles faced in the aerospace sector?

 The aerospace industry encounters several significant challenges, including:

  • Digital Transformation of Manufacturing: While digital transformation streamlines industries, the aerospace sector struggles to keep pace with this change.
  • Cybersecurity Threat: The growing concern of cyber attacks.
  • Supply Chain Weaknesses: Vulnerabilities in the supply chain affecting production and distribution.
  • Increasing Passenger Numbers: Managing the rising demand for air travel.
  • Skills Shortage: The industry faces a shortage of skilled professionals to tackle its growing needs.

 

How are aerospace parts typically manufactured?

 Milling stands out as a prevalent manufacturing technique in the aerospace industry, primarily used for making various cuts and shapes in work pieces. This can range from simple cuts to intricate designs and detailed layers. The most widely used milling processes include vertical milling, which is essential for creating precise components in aerospace manufacturing.

 

Can you explain what aerospace product and parts manufacturing involves?

 The aerospace products and parts manufacturing sector is dedicated to the development and production of aircraft, aircraft components, missiles, and space vehicles. This industry encompasses a wide range of products essential for aviation and space exploration.

 

What does the NAICS code 33641 represent?

 The NAICS code 33641 is designated for Aerospace Product and Parts Manufacturing. This code is used to classify businesses involved in the development and manufacturing of aerospace products, including aircraft and spacecraft components, among others.

Follow AIP Precision Machining on Linkedin

linkedin logo

Machining TORLON: A Plastics Guide

May 30, 2018

An Informational Brief on Polymer Machining

 

AIP Precision Machining has worked with many thermoplastics over the past three decades, including TORLON: a PAI, or polyamide-imide, engineered by Solvay Specialty Polymers.

 

Due to its reliable performance at severe levels of temperature and stress, TORLON is ideal for critical mechanical and structural components of jet engines, automotive transmissions, oil recovery, off-road vehicles and heavy-duty equipment.

 

AIP has over 35 years of experience machining complex components from TORLON and various other thermoplastic materials. We are providing this Machining TORLON Guide as yet another insightful technical brief about our polymer component manufacturing process, and how it differs from that of metal machining, injection molding, or 3D printing.

 

Plastic CNC Machining

Before discussing the process of machining TORLON, it’s important to understand exactly what plastic machining is.

 

CNC (Computer Numerical Control) machining is a process in the manufacturing sector that involves the use of computers to control machine tools. In the case of plastic machining, this involves the precise removal of layers from a plastic sheet, rod, tube or near net molded blank.

 

The early history of CNC machining is almost as complex as a modern CNC system. The earliest version of computer numerical control (CNC) technology was developed shortly after World War II as a reliable, repeatable way to manufacture more accurate and complex parts for the aircraft industry. Numerical control—the precursor to CNC—was developed by John Parsons as a method of producing integrally stiffened aircraft skins.

 

Parsons, while working at his father’s Traverse City, Michigan-based Parsons Corp., had previously collaborated on the development of a system for producing helicopter rotor blade templates. Using an IBM 602A multiplier to calculate airfoil coordinates, and inputting this data to a Swiss jig borer, it was possible to produce templates from data on punched cards.

 

Parsons’ work lead to numerous Air Force research projects at the Massachusetts Institute of Technology (MIT) starting in 1949. Following extensive research and development, an experimental milling machine was constructed at MIT’s Servomechanisms Laboratory.

 

Due to the many different kinds of polymers and composites, it’s important to have strong technical expertise of polymer materials when machining plastic components; some plastics are brittle, for example, while others cut similarly to metal. The challenge of plastics is their wide range of mechanical and thermal properties which result in varying behavior when machined. Therefore, it’s important to understand the polymer structure and properties of TORLON if you’re machining it.

 

Thermoplastics vs Thermosets

When it comes to polymers, you have two basic types: thermoplastics and thermosets. It’s crucial to know which one you’re working with due to distinct differences between how these two main polymer categories react to chemicals and temperature.

 

Thermoplastics soften when heated and become more fluid as additional heat is applied. The curing process is completely reversible as no chemical bonding takes place. This characteristic allows thermoplastics to be remolded and recycled without negatively affecting the material’s physical properties.

 

They possess the following properties:

• Good Resistance to Creep

• Soluble in Certain Solvents

• Swell in Presence of Certain Solvents

• Allows for Plastic Deformation when Heated

 

Thermosets plastics contain polymers that cross-link together during the curing process to form an irreversible chemical bond. The cross-linking process eliminates the risk of the product re-melting when heat is applied, making thermosets ideal for high-heat applications such as electronics and appliances.

 

They possess the following properties:

• High Resistance to Creep

• Cannot Melt

• Insoluble

• Rarely Swell in Presence of Solvents

 

Phenolic, Bakelite, Vinyl Ester and Epoxy materials would be considered examples of a thermoset, while ULTEM, PEEK, DELRIN and Polycarbonate materials are examples of thermoplastics.

The thermoplastic category of polymers is further categorized into Amorphous and Crystalline polymers per the figure below:

 

Machining Ultem
 

TORLON is considered an amorphous, high-performance thermoplastic. Most amorphous polymers are thermoform capable, translucent and easily bonded with adhesives or solvents.

 

 

Various Grades of Machined TORLON

 

What makes TORLON unique is how it possesses both the incredible performance of thermoset polyimides and the melt-processing advantages of thermoplastics. The compressive strength of (unfilled) TORLON PAI is double that of PEEK and 30% higher than that of ULTEM PEI. In fact, TORLON is considered the highest performing, melt-processible plastic.

 

High-strength grades of TORLON retain their toughness, high strength and high stiffness up to 275°C. This and its impressive wear resistance allow TORLON to endure in hostile thermal, chemical and stress conditions considered too severe for other thermoplastics. TORLON is also resistant to automotive and aviation fluids, making it a favorite of aerospace and automotive engineers.

 

One concern of using TORLON is that its moisture absorption rate is not as low as other high-performance plastics, so special care should be taken when designing components for wet environments.

 

There’s more than one particular type of TORLON PAI you can machine, and each has slightly different properties for perfecting this material’s use in different applications.

 

Here are several grades of TORLON PAI we machine regularly at AIP Precision Machining.

 

TORLON 4203

TORLON 4203 is the unfilled or natural grade of TORLON PAI that outperforms other grades with the best impact resistance and the most elongation. TORLON 4203 PAI can be used for a variety of applications but due to its good electrical properties, it is commonly machined for electronic equipment manufacturing, valve seals, bearings and temperature test sockets.

 

TORLON 4301

TORLON 4301 is a wear-resistant grade of TORLON PAI containing PTFE and graphite. It has high flexural and compressive strength with a low coefficient of friction, as well as good mechanical properties. Typical applications of 4301 are anything that requires strength at high temperature with wear resistance and low friction. This material is useful for parts such as thrust washers, spline liners, valve seats, bushings, bearings and wear rings.

 

TORLON 4XG

TORLON 4XG is a 30% glass-reinforced extruded grade of PAI well suited to higher load structural or electronic applications. When you need a high degree of dimensional control, this grade offers the high-performance you need. Various uses of TORLON 4XG include burn-in sockets, gears, valve plates, impellers, rotors, terminal strips and insulators, among others.

 

TORLON 4XCF

TORLON 4XCF is a 30% carbon-reinforced extruded grade of PAI that has the lowest coefficient of thermal expansion and the most impressive fatigue resistance of all plastic materials. This uncommon grade works well as a replacement for metal applications as well as mission-critical aerospace components, in addition to impellers, shrouds and pistons.

 

 

Machining TORLON

 

Annealing TORLON
TORLON PAI can be received in the form of rods, sheets, tube or film. Stress-relieving before machining through an annealing process is crucial, as it reduces the likelihood that surface cracks and internal stresses will occur from the heat generated. This also helps prevent any warping or distortion of your plastic materials.

 

TORLON additionally benefits from post-machining annealing to reduce any stress that could contribute to premature failure. Extruded TORLON parts, such as those machined from TORLON 4XCF and TORLON 4XG, benefit from an additional cure after machining to further enhance wear resistance; this is unique to PAI. Proper annealing of Torlon can require more than seven days in special ovens at AIP.

 

If the machine shop you are working with does not have a computer controlled annealing oven for plastics, then “head for dee hills” as they are obviously not TORLON machining experts.

 

Machining TORLON

An important consideration to have when machining TORLON PAI is how abrasive it is on tooling. If you’re machining on a short run, carbide tooling can be used, but polycrystalline (PCD) tooling should be considered for lengthier runs, machining for tight tolerance and any time you are working with reinforced grades.

 

Another thing to keep in mind when machining extruded TORLON shapes is that they have a cured outer skin, which is harder than interior sections. The outer skin offers the best wear and chemical resistance. If wear resistance and chemical resistance needs to be optimized, extruded TORLON should be re-cured.

 

TORLON PAI will nearly always require the use of coolants due to its stiffness and hardness. Non-aromatic, water-soluble coolants are most suitable for ideal surface finishes and close tolerances. These include pressurized air and spray mists. Coolants have the additional benefit of extending tool life as well.

 

Many metal shops use petroleum-based coolants, but these types of fluids attack TORLON. Many past experiences have shown parts going to customer without cracks, only to develop cracks over time due to exposure to metal machine shop fluids. Be sure to use a facility like AIP who machines polymers and only polymers.

 

Preventing Contamination

Contamination is a serious concern when machining polymer components for technically demanding industries such as aerospace and medical. To ensure the highest level of sanitation down to the sub-molecular level, AIP Precision Machining designs, heat-treats and machines only plastics, with any sub-manufactured metalwork processed outside our facility.

 

 

TORLON Machining Guide: Supportive Information

Medical Sector Biomaterials Guide

Energy Sector Materials Guide

Aerospace Sector Materials Guide

Amorphous Materials

 

 

Explore Our Inventory

 

or request a quote here.

Follow AIP Precision Machining on Linkedin

linkedin logo

Plastics in Medicine: 3D Additive Manufacturing vs CNC Machining

May 15, 2018

3D Additive Manufacturing vs CNC MachiningThere’s no doubt that plastics have become more and more popular in modern medicine. Short lead times are essential in this industry, and both 3D additive manufacturing and CNC machining provide fast production times. When is your medical application better suited for 3D printing, though, and when does precision plastic machining have the upper hand in plastic manufacturing?

 

There are a few key differences and similarities between these types of plastic manufacturing that you should keep in mind for your medical applications. It helps to have a basic understanding of each manufacturing process, first.

 

Subtractive vs Additive Manufacturing

Subtractive Manufacturing

CNC machining is a type of “subtractive manufacturing.” This means that the process generally begins with a solid block of plastic material which is cut or shaped into the desired product through “removing” excess material.

 

While CNC machining requires more initial setup than 3D printing, it offers repeatability, accuracy for both large and small parts, and a wide range of polymers and composites to choose from, as well as a variety of surface finishes. It scales easily between one-time jobs and high-volume production.

 

Additive Manufacturing

3D printing is “additive manufacturing,” which means the initial material is built layer by layer, rather than removed as in subtractive manufacturing. 3D printing creates three-dimensional objects from reading a digital file’s blueprint. When working with plastics, you’re primarily talking about FDM 3D printing. While FDM is widely considered the most quick and cost-effective way of producing custom thermoplastic parts and prototypes, it also has the lowest dimensional accuracy and resolution of any other 3D printing technology.

 

Another option for additive manufacturing is SLS 3D printing, which fuses together the particles of thermoplastic polymer powders. This version of 3D printing has higher accuracy than FDM; however, it comes at the cost of longer lead times, which can be expensive in the medical industry.

 

Choosing the Right Technology for Your Medical Application

As always, choosing the correct technology is dependent on your particular medical application. What you value in your completed product can help determine which style of plastics manufacturing works best for your needs. Some of your considerations should be:

 

Material Consultancy

Both CNC machining and additive manufacturing work with a wide variety of thermoplastics, but those plastics react to manufacturing in different ways. Some materials machine more easily than others, while certain thermoplastic materials are more prone to warping in 3D printing.

 

Your manufacturer should be familiar with your chosen material and be able to discuss the process of machining or 3D printing it with you. At AIP Precision Machining, we have 35+ years of material and machining expertise and we include consultancy as an integral part of our manufacturing process.

 

Mechanical Properties

CNC machining ultimately provides greater dimensional accuracy and better performing properties than additive manufacturing. Machined thermoplastics possess both great mechanical and thermal properties with fully isotropic behavior. If your product requires unique, strong design with critical tolerances, then FDM 3D printing may not be not ideal; this type of printing is inherently anisotropic, meaning it isn’t the best option for mechanically critical components.

 

Medical applications, in particular, have unique considerations that ought to be taken into account, both for choosing your initial material and determining how it ought to be manufactured.

 

Precision Tolerances

Precision CNC machining provides close tolerances for your applications with a fine, burr-free finish. In fact, 3D printed products for the medical field regularly go into CNC machining post-processing as a secondary step in order to accomplish better tolerances or a finishing cut, as FDM parts tend to have visible layer lines.

 

Extreme tolerances up to 0.002mm can be produced by AIP Precision Machining, which can be necessary in demanding industries such as the medical, aerospace and energy markets.

 

Quick Turnaround

Both CNC machining and 3D printing have quick turnarounds, especially when compared to injection molding. Machining designs are crafted on the same computer applications used by 3D printers, so there is no cost associated with design changes for either type of plastics manufacturing. However, when time is truly critical, 3D printed parts can be delivered in 24 hours. Quality and functional usefulness, in this case, may be sacrificed for expediency.

 

AIP Precision Machining can guarantee your complex polymers machined in as little as 10 business days, with quality assured from concept to completion.

 

Volume of Production

Smaller batches, such as 1-10 plastic components, can be more cost-effective if produced with additive manufacturing. This is because using a non-standard blank size increases the cost of machining. Plastic machining, however, easily scales between small and large outputs.

 

If you require a high-quality product that possesses extreme mechanical and thermal strength, it is worth precision machining for that reason alone.

 

The Final Consideration? Experience.

The medical field often has no room for error when it comes to implants, spinal devices and orthopedic equipment. This is why—no matter what type of plastic manufacturing you choose—you want to be sure you’re working with an expert who understands the importance of sterilization, biocompatibility, and other traits that may be necessary for your application.

 

AIP is FDA and ISO 13485:2016 registered and has been audited by some of the most stringent OEMs in the orthopedic and medical device industries. We process our plastics with strict hygienic procedures.

 

Whoever you work with, be sure they understand the needs of your industry and have the experience to prove it.

 

Click here to learn more about the utility of each technology with regard to precision efficiency, materials and more.

Or, request a quote with AIP Precision Machining here.

Follow AIP Precision Machining on Linkedin

linkedin logo

Settling the Debate: 3D Printing, Injection Molding or Plastic Machining

July 27, 2017

To a certain degree, 3D printing, injection molding, and plastic machining technology overlap in their capabilities and offerings. But which fabrication process is most appropriate for your project? What are their key differentiators? The following article assesses the utility of each technology with regard to precision, efficiency, materials and more.

 

Capabilities

 

An example of 3d printing example of Yoda

3D printing is an additive manufacturing process that prints layers of plastic substance in three dimensions onto a single point. The popularity of 3D has grown significantly over the past few years, and it can easily be used for rapid prototyping, DIY production and manufacturing by small-scale engineers or designers. Many of the advances in 3D printing have been focused on bringing down prices, rather than technological advancement so that it can be more accessible to “mom-and-pop” users who are otherwise not eligible for the more expensive and advanced manufacturing processes.

 

An example of injection molding

 

Another additive technology, injection molding is a manufacturing process in which parts are produced by injecting materials in liquid form into a mold. Commonly performed with thermoplastic polymers, it can be used with a variety of other metal and glass materials. Small pellets of material are heated into a molten liquid which is then injected into a mold at high pressures and rapidly cooled—causing it to harden—and then ejected from the mold, exposing the part to air. Two of its key benefits include a fully automated process—permitting very high rates of production—and also that its molds allow for highly detailed and intricate parts.

 

An example of plastic molding

 

Finally, plastic machining, or CNC (Computer Numerical Control) plastic machining or CNC milling, involves the precise removal of layers from a material. Typically beginning with a block of the desired plastic material, plastic machining involves removing material layers at a time and allows for many different materials to be used. Introduced by MIT during the 1950s, this technique utilizing drilling tools to carve plastics—and because it’s computer-controlled, extremely precise and tolerant products are achieved.

 

 

 

Comparing the Options

 

 

3D Printing Injection Molding Plastic Machining
Cost Very low cost when you need 1-10 rapid design iterations on a prototype part. Because creating (or updating) a mold can end up being much more expensive than the actual order itself, this is only cost-effective with very large-scale projects. Significantly cost-effective when you need a few parts up to a few thousand.
Design Designs can be highly personalized and unique—this technology is often used by artists and creative professionals. Allows for deep features, square holes and living hinges to be produced easily. High design flexibility at lower costs are allowed.
Material Very limited in comparison to other plastic fabrication and unable to achieve the same smooth surfaces as the other technologies. Injection molding has a much wider range of materials available for use compared to 3D printing but is more limited than CNC machining. Broadest range of materials are allowed—CNC plastic machining also achieves the smoothest finish with the fewest imperfections.
Production Fast and extremely convenient—small products can be machined in seconds. Requires time to make the mold but once the mold is finalized, production moves quickly. One of the fastest forms of fabrication and can easily scale between small and large outputs.
Tolerance 3D printed prototypes are not typically finished parts and are much more likely to delaminate. Best for home and personal consumer-grade products. Parts are molded at tighter tolerances than 3D printed parts but are not as tolerant as plastic machined parts. Highest tolerances available—parts are able to reach +/- 0.002 mm and are best for demanding industries like aerospace and defense, medical and life sciences and power generation.

 

Why Plastics Machining Ranks Best

 

From the above chart, you can see the differentiators of each fabrication process. However, we’ve found that CNC plastic machining is by far the most precise and beneficial process for custom applications.

 

Cost-wise, plastics machining is the most effective for any project that requires unique, strong designs. 3D printing is the cheapest form of fabrication but you get what you pay for with that medium… and the quality typically just isn’t there. Injection molding, meanwhile, offers much stronger products than those that are 3D printed, but modifications to a mold are extremely expensive and injection molded products are not as tolerant as plastic machined parts.

 

Looking at design abilities, each medium offers a wide range of capabilities but again, if it’s quality that your project needs, CNC machining is the way to go—3D printed materials are really only suited to personal or home use and injection molded products cannot hold up to the rigors of the aerospace and defense, medical or power and energy industries (among others). Further, machining designs are crafted on the same computer applications that 3D printing uses so there’s no cost associated with changing the design of the product (unlike injection molding, where a new mold would then need to be created).

 

It is important to note that CNC plastic machining is a specialized craft… not just anyone interested in 3D modeling can create the design for a plastic machined product. Here at AIP Precision Machining, we have over 35 years of technical design expertise and we work diligently with our clients to craft products that exactly meet their project requirements.

 

If you’re looking to decide on a fabrication process via the material selection available to you, plastics machining offers the widest range of diverse thermoplastics for your project. 3D printing has not advanced its material range in many years and because injection molding requires liquidating its materials, you won’t be able to use the stronger, heat-resistant plastics that might be best for your needs. CNC machining is the only process that allows you to choose from the full assortment of material selections.

 

3D printing and CNC machining tie for the fastest production times, as both take minutes to complete. Injection molding, however, requires more time to make the mold (which can take weeks to finalize).

 

Finally, if your project requires the highest levels of tolerance, precision machining produces the most precise and extremely tolerant products. It’s the only fabrication process suited for critical pieces.

 

Want More Information?

 

Of 3D printing, injection molding and CNC plastic machining, one process is not necessarily better than the other—it’s dependent on your project requirements. However, plastics machining is by far the most specialized and precise option for high-quality, critical parts needed in industries like aerospace and defense, medical and life sciences and power and energy.

 

Here at AIP Precision Machining, we commonly craft pieces that are able to survive the rigors of space, the inside of a human body or the corrosive chemicals used on an oil rig. We offer state-of-the-art technology and extensive expertise to provide you with the highest quality products. Contact us to learn more about our process and what CNC plastics machining could do for you.

Follow AIP Precision Machining on Linkedin

linkedin logo