CNC Machining vs. Rapid Prototyping When to Combine Both Technologies

CNC machining (CNC) and rapid prototyping (RP) are two disruptive technologies in the manufacturing industry, the former for high precision and volume production, the latter for rapid prototyping and complex structure forming. However, many organisations face confusion when choosing a technology path: when should either technology be used alone? When do you need to combine the two to achieve synergistic effects? In this paper, we will analyse the complementary nature of the two technologies from the technical characteristics, applicable scenarios and integration strategies to help you optimize the manufacturing process and reduce costs.

I. Comparison of CNC Machining and Rapid Prototyping Technologies

1. CNC machining: synonymous with precision and stability

Technical characteristics: through digital programming control tool movement, metal, plastic and other materials cutting, milling and drilling, precision up to ± 0.01mm, surface roughness as low as Ra0.2μm.

Advantage: suitable for mass production, high-precision parts (such as engine block, mould cavity) and complex surface processing (such as automotive cover parts).

Limitations: high cost of moulds in the early stage, long cycle of small batch trial production, and difficult processing of complex internal cavity structure.

2. Rapid prototyping: an innovative tool for agility and freedom

Technical characteristics: based on the principle of layered superposition, through 3D printing, laser sintering (SLS), fused deposition (FDM) and other ways to directly generate a solid model, without the need for moulds, the material utilization rate is close to 100%.

Advantage: Suitable for single piece/small batch prototyping (e.g. concept car shells), complex skeleton structures (e.g. lightweight aerospace parts) and rapid mould manufacturing.

Limitations: Limited material properties (e.g. strength, temperature resistance), high surface roughness (Ra3.2μm or more), high cost of mass production.

3. Comparison Summary

II. 4 Typical Scenarios of When to Combine Two Technologies

1. Staged manufacturing of complex parts

Case: aerospace engine turbine blades

Rapid prototyping: first use SLS technology to print wax prototypes with complex cooling channels to verify aerodynamic performance.

CNC machining: Combined with the investment casting process, the casting cavity is refined by CNC to ensure that the surface finish of the blade reaches Ra0.4μm.

Advantage: Shorten the development cycle by 30% and reduce the cost of trial and error by 50%.

2. Hybrid manufacturing of rapid moulds

Case: automotive interior injection mould

Rapid prototyping: make paper master mould through LOM technology to quickly verify the mould structure.

CNC machining: Using the master mould as a reference, use 5-axis CNC to machine the steel mould core with an accuracy of ±0.02mm.

Advantage: Mould delivery cycle is shortened from 3 months to 3 weeks.

3. Functional enhancement of functional prototypes

Case: Medical device metal implant

Rapid prototyping: Manufacture of porous osseointegrated structures using metal 3D printing (e.g. SLM).

CNC machining: CNC finishing of critical contact surfaces (e.g. threaded holes) with roughness optimised to Ra0.8μm.

Advantage: balance between biocompatibility and mechanical strength, FDA-approved efficiency increased by 40%.

4. Small-lot customised production

Case: High-end customised watch case

Rapid prototyping: Rapid production of personalised design prototypes using light-curing (SLA) technology.

CNC machining: Titanium alloy case is machined by precision mill-turn machine with tolerance control of ±0.005mm.

Advantage: Customers only need 10 days from design to delivery, and the premium ability is increased by 30%.

III. 3 Core Strategies for Technology Integration

1. Data chain synergy: seamless connection from CAD to CAM

Method: Realise design model directly drive RP and CNC equipment through unified software platform (e.g. UG, MasterCAM) to avoid format conversion error.

Value: Reduce repeated modelling time by 60% and reduce the risk of human error.

2. Material and process matching

Metal field: RP manufacture near-net shape blank, CNC complete high-precision cutting (such as aluminium alloy impeller).

Plastic: FDM printing functional prototypes, CNC machining glass fibre reinforced nylon jigs and fixtures.

3. Cost and efficiency balance

Economy formula:

Total cost = (RP cost × quantity) + (CNC cost × finishing ratio)

When the batch size <50 pieces, the priority is RP + CNC hybrid solution; when the batch size >500 pieces, CNC independent production is more advantageous.

IV. JLCCNC: CNC and rapid prototyping integration of manufacturing leaders

JLCCNC specializes in the field of precision manufacturing, providing CNC machining and rapid prototyping synergistic solutions for automotive, aerospace, medical and other industries.

Successful case:

Developed battery tray for a new energy vehicle enterprise, 3D printing lightweight structure + CNC high-precision sealing surface machining, 15% weight reduction and 20% cost reduction.

Helped a medical device company to achieve mass production of customised hip implants, reducing lead time by 50%.

Contact JLCCNC today to unlock the unlimited possibilities of CNC and additive manufacturing!