CNC printing
From the CNC milling machine to the 3D printer
If you have already marvelled at the precision of components from CNC 3D printing, you will have some idea of the impressive possibilities of this technology. Did you also know that, in theory, any CNC milling machine could be turned into a 3D printer?
When we talk about CNC 3D printing, we are talking about a technology that is constantly evolving with new requirements, innovations and areas of application. Simple 3D printers for private use rarely process other materials such as plastics or resins. In the industrial environment, more flexible solutions are required, as challenging materials such as metal are also used.
With the CNC milling machine as a 3D printer, your machine concept is customised to create components with particularly fine or complex geometries. State-of-the-art CNC 3D printers are also suitable for small series. Depending on the component geometry, the process is even cheaper than injection moulding for quantities of 100 to 1000. In addition, 3D printers make your prototyping more efficient and make it possible to produce wear and spare parts that are no longer available in series production.
Special features
What you need to consider with 3D printing
Speed according to material
The speed depends in particular on the material melting temperature and the selected printing process. DMLS makes the CNC 3D printing process finer, but also slower, compared to the coarser FDM process. The CNC drive concept is also crucial. More important than the process speed itself, however, is the volume flow, i.e. the flow rate of the melting material.
Combination of materials
If you are producing complex composite constructions, advanced technologies such as machines with 4-fold print heads are suitable. This allows you to produce the components with all the required materials within one printing process. The concept of a CNC milling machine could also be combined with 3D printers so that additive and subtractive manufacturing can take place on one machine.
Accuracy & complexity
Depending on the material, process, component size and printing speed, a very high level of precision and complexity can generally be achieved. The geometric fineness of 3D printing technology in FDM, for example, depends on the nozzle diameter. This process can be used to print to approximately 1/10 of a millimetre. However, it is generally coarser than additive laser melting, for example.
Special features
Deburring & waste
Hybrid concepts, which combine the advantages of CNC milling and 3D printers in one machine, allow the typical burr on printed components to be removed. Alternatively, you can use classic finishing procedures that are common in CNC manufacturing. In any case, less waste is generated by additive processes, as only as much material is used as is calculated for printing.
Software & Maintenance
The efficiency of a CNC 3D printer also depends on its software. Regular updates can increase the printing speed or compatibility with hybrid printing/milling processes. You can define different heat settings for each print head and also adjust the heating board. In addition to the software, the printing components should also be serviced regularly.
Energy supply & material heating
Whether a CNC milling machine consumes less energy than a 3D printer depends in particular on the material requirements for the heating bed and nozzles - printing is more efficient with an optimised material recipe and active temperature management. The time it takes for the material to cool down is also important. Products from the CNC milling machine are ready for use more quickly than a printed component.
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References
FAQ
Answers to the most frequently asked questions about 3D printing
How good the energy efficiency or machine throughput of both processes is depends primarily on the production project. It is unusual for a 3D printer to be intended for series production. Nevertheless, its effective material consumption is significantly more efficient than that of a CNC milling machine. If components are intended for mass production, milling technology has a higher throughput. Please note, however, that laser melting leads to higher energy costs than machining processes.
As composite constructions with subsequent deburring can be produced on one machine, prototyping using hybrid CNC 3D printers is always more advisable than using a standard CNC milling machine. Due to the high-precision adjustment, materials and powder beds can be translated into very complex geometries. With the appropriate software, 3D models can be transferred directly to the machine.
In addition to prototyping, CNC 3D printing can also be used to produce spare parts, exhibits and components from fixture construction, i.e. wear parts. 3D printers fulfil their full potential with particularly complex and fine components. Components can therefore also be produced that seamlessly integrate other parts or form a cage around them.
If the heads are compatible with the Linear guide or other drive unit of a CNC machine, any print head can be connected in principle. However, the software settings are also crucial. Different programmes are used for 3D printing than for the milling process. These adjustments are particularly exciting for 4-axis printing. If materials also require a heating board, these requirements should already be taken into account when designing a CNC machine.
Compared to 3D printing kits from the private sector, the technology differs not only in its precision, but also in the variety of possible applications. In addition to plastics, metals can also be processed. As the technology continues to mature, industrial systems are designed to be as upwardly compatible as possible. While typical 3D printers are basically only intended for model making, it is not possible to start mass production with professional CNC 3D printers, but the throughput is still better for short series.