Revolutionizing Machining: The Impact of 3D Printing

 The tool professionals consider how impact of 3D printing will change machining. They recognize the advantages of 3D printing, especially in prototype construction, but are convinced that additive manufacturing will not completely replace CNC machining, but will complement it.

The Impact of 3D Printing in Machining

The introduction of impact of 3D printing in the production of prototypes has significantly improved product development. It has become faster and more economical. This technology is now being treated as an alternative to CNC machining.

However, this approach should be questioned and it needs to be clarified whether 3D printing can completely replace machine production in the smart factory.

Iscar’s Expert Opinions

The answer from Iscar’s experts: Despite the positive prospects of impact of 3D printing, it cannot completely replace CNC machining as the dominant technology for the production of metal components. “However, there is no doubt that additive manufacturing (AM) will have a significant impact on a whole range of production processes,” says Erich Timons, CTO of Iscar.

Characteristics of 3D Printing and CNC Machining

Both technologies create the geometry of a component by forming the workpiece material to be processed layer by layer. But which of the processes is more effective? And how will the combination of both solutions specifically affect production in the future?

To answer these questions, the main characteristics of impact of 3D printing and CNC machining must be examined in detail. These include workpiece materials and their physical properties, the shapes created, and the precision of the machining.

Metals are the most important workpiece materials in CNC machining. Despite a significant increase in the proportion of metals, non-metallic materials still dominate in 3D printing.

At the same time, advances in powder metallurgy have made it possible to print parts made of difficult-to-machine materials such as nickel-based superalloys. This opens up new perspectives for additive manufacturing.

Physics also plays an important role: metals are isotropic. This means that they have the same physical properties in all directions. In contrast, impact of 3D printing products are anisotropic: for example, their strength can be higher in the horizontal direction than in the vertical direction.

Structural Behavior and Reliability

The structural behavior, stiffness, and reliability of components made of isotropic metals can be precisely calculated. However, it is more difficult to make accurate predictions for 3D-printed products.

This is one of the reasons why the introduction of AM in the production of key metal elements is progressing rather slowly: local CNC Machining services is the predominant process for the production of critical components.

Advantages and Disadvantages of Both Methods

CNC machining is mainly limited by the fact that the access of a cutting tool to the surface to be machined is limited. Impact of 3D printing is different: it is more flexible and significantly expands the possibilities for producing complex shapes. Metal removal through machining enables the machining of components with a wide range of dimensions.

Flexibility and Complexity in 3D Printing

Impact of 3D printing is much more limited: in principle, a large-format component can be manufactured additively. In this case, it is advisable to divide the part into several smaller components and then join them together.

However, this process significantly increases production time and also raises the question of the required strength and rigidity.

3D printers currently achieve a dimensional accuracy of 0.25 millimeters. Custom CNC machining services is much more precise and achieves tolerances that are at least two to three times tighter. The process also works with greater repeatability and produces higher surface qualities.

The issues of cost-effectiveness and sustainability must also be taken into account. A 3D printer is significantly cheaper than a modern CNC machine. CNC machining also produces chips that must be recycled. With 3D printing, on the other hand, less waste is produced, the workpiece material is used efficiently, and the energy consumption is lower.

Approaching the Final Form

In metal processing, additive manufacturing produces precise workpieces that are very close to the desired final shape. The production of complex components requires CNC machining with minimal material removal, as well as high precision and surface quality.

“3D printing enables fast and precise prototyping results, thus shortening valuable production time to achieve the optimal solution,” says Erich Timons.

“However, impact of 3D printing processes do not replace CNC machining; rather, they complement machining processes.” Machines that combine precise multi-axis machining with 3D printing, integrated into one system, are already on the market.

Precision in Additive Manufacturing

Using 3D printing for manufacturing components impacts milling tools that form complex parts and must meet increasing demands for efficiency and precision. To achieve optimal material removal rates with low allowances, high-speed machining (HSM) with high feed rates and speeds is often used in practice.

This requires precise cutting tools that enable reliable machining with as few machining passes as possible and very good surface quality. Examples include solid carbide (VHM) end mills, modular tools with interchangeable cutting heads, and precise profile milling cutters with indexable inserts from Iscar for economical machining of complex shapes.

Manufacturers of cutting tools consider additive components when assembling their portfolio. For example, Iscar has expanded its range of multi-edged solid carbide milling cutters for high-speed machining.

The current range focuses on end mills with special cutting geometries, used in 5-axis high-speed machining of complex profiles and offering the right solution for efficient finishing processes. Additionally, these insert geometries can be found in single-edged indexable insert tools that cover larger nominal milling cutter diameters.

Iscar has integrated these cutting edges into its modular MULTI-MASTER tool line with interchangeable milling heads, combining the advantages of solid carbide and indexable insert concepts.

An example of the synergy between impact of 3D printing and CNC machining can be seen in the production of complicated configurations of special indexable insert tools.

3D printing also offers advantages in tool design: it optimizes a milling cutter’s design, especially the inner surfaces and coolant channels for targeted cooling directly at each cutting edge.

Engineers see 3D printing as a suitable process for finding optimal and sustainable solutions for special and newly developed products. Impact of 3D printing of indexable inserts represents a significant step forward.

Additive production of prototypes does not require expensive die sets and enables reliable testing of different design variants of the inserts, significantly shortening development time, lowering production costs, and minimizing waste.

3D printing will not completely displace CNC machining from production halls in the future. Erich Timons sums it up: “The symbiosis of these two technologies will be a characteristic feature of metal processing in the near future.”