High Production Scale Milling Starts Here: Your Guide to Scalable Fabrication
Achieving a high production scale efficiently and at a low cost is crucial for staying ahead in the manufacturing industry. Scaling up fabrication processes, such as milling, demands integration of advanced technology and strategic planning. If you’re looking to learn how to scale up your milling production, keep reading to learn useful tips and techniques.
How to Achieve High Production Scale Milling
Scaling up milling operations involves more than just increasing your output. You must analyze your team’s current workflow while also investing in innovative manufacturing machinery and emerging technologies. In doing so, you can cut production times while also reducing waste and enhancing productivity.
We’ll introduce you to some of the modern industrial machinery that has enabled our facility to execute large scale production runs while maintaining high efficiency.
CNC Milling Instead of Manual Milling
If your facility primarily utilizes manual milling, the transition to CNC (Computer Numerical Control) milling would be highly beneficial. CNC milling trumps traditional, manual methods in productivity and efficiency, making it a key player in high production scale milling.
Here is what makes CNC milling so effective in high production scale milling facilities:
Automated controls which offer unparalleled consistency and repeatability, especially compared to manual, human-controlled methods. This automation is essential for producing large quantities of parts.
Complex designs are easier and quicker to execute through computer-aided programming. It eliminates the room for error and inconsistency that is present in manual methods. CNC milling machines easily recreate intricate designs in large and scalable productions.
With little material limitations, CNC technology works with metals, acrylics, and plastics. This versatility meets diverse industry requirements.
At BSG, we use a 5-Axis Vertical Machining Center MX-330 PC10 CNC milling machine for our projects. To speed up production runs, it’s equipped with additional automated features like an automated pallet changer for batching a large number of parts, and an automated tool changer so parts can be produced overnight.
Learn more about our CNC Milling Machine!
In addition to CNC milling, other pieces of industrial-grade equipment can play a role in optimizing your production runs. Let’s take a look.
Utilize Alternatives: Laser Cutting, Plasma Cutting, 3D Printing
There are other options for scaling production outside of automated milling alternatives. Let’s face it — in a large production run, a single CNC milling machine can only do so much capacity-wise. Other supplementary non-milling equipment can be used for capacity challenges.
Laser Cutting
Laser cutting is best known for blending high precision and speed. It requires CNC programming, just like CNC milling, but uses a high-power fiber or CO2 laser.
Why Choose Laser Cutting for Large-Scale Productions
Reduces Material Waste: The laser used in industrial-grade laser cutting machines is powerful enough to make precise cuts without leaving behind as much waste. It vapourizes or melts the material in the cutting path rather than leaving behind chips or excess debris.
High Precision Without Sacrificing Efficiency: Laser cutting machines make quick, accurate cuts, making it highly efficient, while also being able to create intricate designs and patterns.
In a high volume production environment, you’ll often have to produce thousands of identical metal parts. In cases like these, laser cutting plays a crucial role in speeding up the production process. Laser cutting can quickly and easily pre-cut flat sheet metal components before they go to CNC milling for the last steps, like shaping or hole drilling.
At BSG, our powerful Amada laser cutting machine has enabled us to execute projects with superior versatility, accuracy, and adaptability.
Learn more about our laser cutting machine!
Plasma Cutting
Like laser cutting, plasma cutting offers a fast and efficient method for cutting through thick metal materials. Its ability to handle tough materials with ease complements milling processes, especially when dealing with large and robust parts.
Why Choose Plasma Cutting for High-Scale Productions
Cost-Effective: Plasma cutting’s automated, energy-efficient approach and high accuracy effectively lowers waste disposal costs, labour costs, and energy costs.
Material Versatility: Plasma cutting can work with virtually any conductive metal. Additionally, it’s not limited to thin sheet metal, and can also work with thicker metal parts.
In your large-scale productions, plasma cutting can create the broad material shape before the CNC milling process takes over for the fine details.
Our state-of-the-art plasma cutting machine has helped our facility bring customized manufacturing solutions to our clients.
Learn about our plasma cutting machine!
3D Printing
A recent innovation, 3D printing has come to be a major player in our facility when it comes to producing prototypes and other small parts for larger projects. It is an additive manufacturing process which creates parts layer by layer. It only utilizes the amount of material you need for the final product. This eliminates material waste, as well as the need for post-processing.
Why Choose 3D Printing for High-Scale Productions
Low-Waste Production: Unlike subtractive methods like milling, 3D printing uses only the material needed to create the part. There’s no waste to be disposed of, nor cleanup time to account for. 3D printers can produce highly complex parts without the cost of excessive material usage.
Fast Prototyping & Design Iteration: In high-scale production, speed is everything. Before heading into the full-scale production phase, a 3D printer can assist in the development phase with superior adaptability and productivity. Manufacturers often use 3D printing to rapidly test design iterations and discover what works best functionally and aesthetically for the project.
Contract Manufacturing for High Capacity Projects
We understand that large-scale production is not always easy, especially if you lack the modern manufacturing equipment needed to reach optimal project turnaround times. Although great for long-term efficiency and cost-savings, obtaining these industrial-grade machines requires a high initial investment.
That’s why we at BSG are happy to work with fellow Kitchener-Waterloo manufacturers to assist in delivering high-quality products in a timely manner.
For many businesses, especially those aiming for rapid growth or entering new markets, contract manufacturing can be a practical solution for scaling production. Partnering with established manufacturers like BSG allows companies to expand their production capacity without the substantial upfront investment associated with new equipment and facility expansion.
Let us be your partner in efficiency — Find out how BSG can drive efficiency and productivity in your large-scale milling projects by requesting a quote today!