CNC (Computer Numerical Control) machining is an integral part of modern manufacturing, which uses precise computer programs to control machine tools to process various parts. However, when performing CNC machining, companies often only focus on explicit costs, such as equipment depreciation, consumables, working hours and factory rent, etc., but easily ignore the hidden costs hidden in daily operations. Although these hidden costs are not easy to detect or quantify, they still have a profound impact on the company’s total costs and competitiveness.
Today, in this blog, the Longsheng team will take everyone to explore the hidden costs in the CNC machining process, so as to maximize profits when purchasing CNC machining services.
How to Compare CNC Machining Prices?
When comparing CNC machining prices, you can comprehensively consider the following aspects to ensure you receive both economical and high-quality machining services:
Clarify your needs: First of all, make sure you know your processing needs, including the material, size, shape, quantity, accuracy requirements, etc. of the parts. This will help suppliers provide more accurate quotes.
- Request a Detailed Quote: Provide your machining needs to multiple CNC machining suppliers and request detailed quotes from them. The quotation should include material cost, labor cost, machine time, installation fee, post-processing fee and possible transportation cost.
- Consider materials and complexity: When comparing different quotes, make sure they are for parts of the same material and complexity. Special materials and complex designs often result in higher processing costs.
- Check for additional services: Some suppliers may include additional services in their quotes, such as quality control, assembly or finishing, etc. Make sure you understand whether these services are included in the quote or if there is an additional cost.
- Evaluate supplier reputation: In addition to price factors, the supplier’s reputation, historical performance, customer reviews, etc. should also be considered. These factors will influence your final choice.
- Comprehensive comparison: Comprehensively compare the quotations, services, reputation and other factors of different suppliers to choose the supplier that best suits your needs.
Case
Assume that Longsheng and Supplier A both need to process an aluminum alloy part
Parts requirements:
- Material: Aluminum alloy 6061
- Dimensions: 100mm x 50mm x 20mm
- Processing content: milling, drilling, surface treatment
- Quantity: 100 pieces
| Project | Longsheng | Supplier A |
| Material cost | 1800 | 2000 |
| Processing time | 41.67 | 50 |
| Equipment cost | 9167 | 10000 |
| Labor cost | 2500 | 2500 |
| Surface treatment | 1200 | 1000 |
| Total cost | 14667 | 15500 |
Conclusion:Longsheng’s total cost: 14,667 yuan <Supplier A’s total cost: 15,500 yuan
Although Longsheng’s equipment costs and surface treatment expenses are higher, the overall cost is lower due to shorter processing time. Therefore, it is more economical to choose Longsheng.
What Are the Hidden Costs in CNC Machining?
There are indeed many hidden costs in CNC machining. Below we will introduce in detail the main hidden costs in CNC machining:
- Maintenance costs of molds and fixtures: Molds and fixtures will wear out during use and require regular maintenance or replacement. This is an ongoing cost. There are also costs associated with mold storage and management.
- Additional costs of tools and consumables: In addition to molds, CNC machining also requires various cutting tools, such as cutters, milling cutters, etc., and these tools need to be replaced regularly. Consumables such as coolant, cutting fluid, etc. are also necessary, and their consumption will increase costs.
- Programming and setup costs: Programming a CNC machine tool to generate the required machining paths requires time and technical knowledge, which can result in additional costs. Machine tool setup and calibration are required every time a part is replaced or process parameters are adjusted, which is also a cost.
- Quality control and inspection costs: In order to ensure that the quality of parts meets standards, various quality control and inspection work may be required, such as dimensional measurement, material testing, etc., which will increase costs.
- Cost of downtime and waiting time: Equipment failure, maintenance, or time waiting for materials/parts to arrive can interrupt production, thereby increasing costs. This loss of time is implicit, but the impact is significant.
- Technology and training costs: Operating CNC machine tools requires professional skills and knowledge. If employees lack these skills, training may need to be provided, which will increase costs. When new technology or equipment is introduced, employees also need to be trained.
- Energy and environmental protection costs: In the CNC machining process, the consumption of energy such as electricity and gas also forms part of the cost. Complying with environmental laws and measures to reduce waste generation can lead to rising costs.
- Management and coordination costs: management and coordination of costs are crucial, which requires effective coordination by the management team in all aspects to ensure that the production process can proceed smoothly. At the same time, the salaries and benefits of these managers also form part of the cost. Many uncertain factors will be encountered during the production process, such as equipment failure, personnel changes, etc., therefore, a lot of manpower and material resources will be spent. If difficulties are encountered in the production process, the management team needs to communicate and coordinate effectively, which also involves time and cost considerations.
Why Is CNC Machining Expensive?
There are many main factors for the high machining cost of CNC:
- CNC machining is a process involving high-tech machinery precision manufacturing, usually requires the use of expensive equipment and tools, so its complexity and precision requirements are very high. Due to the small machine structure size, poor rigidity and other reasons, generally only a relatively simple process method can be used for parts machining . The manufacturing precision and technical challenges required increase as the design becomes more complex or requires stricter tolerances, which further leads to higher manufacturing costs.
- The cost of materials is relatively high, especially when significantly increased when high-performance materials such as titanium or hardened steel are used. In the manufacture of titanium alloy parts and hard brittle metal materials, if there is no advanced technology, expensive equipment must be used to achieve the required performance. Alternatively, processing of these specific materials may require specific cutting tools or unique processing techniques, which can lead to further increases in costs.
- Before the CNC machine tool starts processing, it needs to be deeply configured and coded, especially for those complex parts. Therefore, the setting time is generally longer than the ordinary machine tools. The complexity and volume of the parts are closely related to the length of time of the setting. As these two factors gradually grow, the setting time required will also increase, which will undoubtedly increase the total cost of machining each component.
How Is CNC Machining Cost Calculated?
The calculation of CNC machining costs involves many aspects. The following are the detailed calculation methods and considerations:
Machine time cost
Machine time is an important factor in determining CNC machining costs. Hourly rates for CNC machine tools vary based on the type of machine (such as a 3-axis, 4-axis, or 5-axis machine) and the capabilities of the machine. Generally speaking, high-precision, high-performance machine tools have higher hourly rates. The more complex the machining process, the more time it takes, resulting in higher machine time costs.
The specific calculation method is: machine time cost = machine tool hourly rate × processing time. Among them, the processing time needs to be estimated based on factors such as the size of the part, processing complexity, accuracy requirements, and machine tool performance.
Material cost
Material costs are based on material type, grade and quantity. The larger the part, the more material is used and the higher the cost. The unit prices of different materials vary depending on the material. For example, the unit prices of common aluminum 6061 and S45C are different. In addition, the material loss rate also needs to be considered, Because during the actual processing process, due to the influence of cutting, grinding and other processes, there will be a certain loss of material.
The specific calculation method is: material cost = material unit price × material usage × (1 + loss rate). Among them, the amount of material can be calculated by the volume and density of the part.
Labor and management costs
Labor costs include things like operator time and machine maintenance. Operators are responsible for the operation, monitoring and troubleshooting of machine tools, and their salary levels will directly affect labor costs. In addition, machine maintenance is also a cost that cannot be ignored, including regular maintenance, repair and replacement of wearing parts.Overhead expenses include things like facility maintenance, utilities (such as water, electricity) and tool costs. These costs, while not directly related to the processing process, will have an impact on the final price.
The specific calculation method is: labor and management costs = operator salary × processing time + machine maintenance costs + management cost allocation. Among them, the operator’s salary needs to be determined based on factors such as local wage levels and factory size; machine maintenance costs can be estimated based on the machine tool’s maintenance records and expected maintenance cycles; management expense allocation needs to be allocated based on factors such as the factory’s operating costs and processing volume.
Other expenses
In addition to the above costs, there are other costs that need to be considered, such as programming fees, tool fees, inspection fees, packaging and transportation fees, etc. Although these costs are not dominant, they will have some impact on the total cost.
To sum up, the comprehensive calculation method of CNC machining cost is:
Total cost = machine time cost + material cost + labor and management expenses + other expenses.
In actual operation, detailed cost analysis needs to be conducted based on specific processing requirements and part characteristics to ensure the accuracy and reasonableness of the quotation.
How to Minimize CNC Machining Costs?
To minimize CNC machining costs, the following key measures can be taken:
1.Avoid deep cavity machining challenges
Deep cavity machining, where the tool travel needs to be extended to create a deep cavity inside the workpiece, using CNC milling machines can cause a series of problems, including tool breakage, accelerated wear, chatter, deflection, wall vibration, coolant supply and chip disposal.
These problems directly increase the frequency of tool replacement and increase the risk of workpiece damage, which in turn has a significant impact on the overall cost. Therefore, an effective cost-saving strategy is to prevent unnecessary cost increases.
2.Relax tolerance range to reduce costs
Tolerance refers to the dimensional difference between the actual manufactured part and the submitted design, usually measured in hundredths or thousandths of an inch. When part tolerances are set too tight, it drives up the overall cost due to the part’s complexity and specific needs. Tight tolerance requirements slow down processing and necessitate the use of higher specification CNC machining equipment. Not only does this mean more investment in equipment, it also increases labor costs due to longer processing times, as operators are required to work for long periods of time.
Therefore, when project conditions permit, it is a wise choice to moderately relax the acceptable processing tolerance range. This can not only improve the efficiency of CNC machining, but also effectively reduce processing costs. The tolerance accuracy provided by Longsheng Company can be as low as +/- 0.005 mm, depending on the actual needs of the customer.
3.Reduce the number of repeated processing
When the product needs to achieve a higher post-processing finish, the processing time of the CNC machine will increase significantly to pursue high quality of the edge. This practice not only increases machine and labor costs, but also accelerates tool wear. Therefore, it is particularly important to reduce unnecessary repeated processing times.
Although many products undergo secondary finishing to improve quality, this undoubtedly adds additional cost. It is an economical choice to directly use the final product processed by CNC as the finished product. Of course, special processes such as heat treatment, special coatings, anodizing, and surface finishing are necessary in some cases, but their necessity and value should be fully evaluated before implementation.
4.Optimize design strategy
The CAM blueprint is the cornerstone of the product design, which is then converted into a CAD design and uploaded to the CNC machine to guide the cutting operation. Through optimized design, CNC machines can use the shortest path to complete the manufacturing of the final product with the least material consumption, thus making efficient use of time and raw materials.
Inaccurate CAD drawings can lead to high costs in the production process, as missing or wrong information may require remanufacturing. Consulting an experienced machinist or engineer during the design phase, although it may increase initial costs, will result in significant savings in the long run, especially for high-volume production. Therefore, it is recommended to invest more in the design process to reduce long-term CNC machining costs.
5.Reasonably control the thread length
Some manufacturers prefer to machine screws and bolts with longer threads for added strength, but in most cases shorter threads are sufficient. The increase in thread length not only prolongs the processing time and increases the material cost, but also causes a waste of resources. Therefore, thread length should be controlled within the range required for optimal strength.
6.Simplify design to reduce costs
Design complexity is directly proportional to CNC machining cost. Complex designs often require a CNC mill with more axes, exponentially increasing the overall cost. However, most complex designs can be assembled by breaking them down into simpler designs and processing them on a three-axis CNC mill. This method can significantly reduce CNC machining costs.
7.Increase production to reduce costs
Increasing production volume is one of the most direct and effective ways to reduce CNC machining costs. As production increases, fixed costs are spread over more parts, lowering the manufacturing cost of each part. In addition, mass production reduces design costs because the same design blueprint can be used to produce hundreds, thousands or even tens of thousands of parts, further reducing tooling costs per product.
8.Adopt rounded corner design
CNC routers are less efficient when handling sharp edges and 90-degree corners because frequent stops and turns are required. In order to improve processing efficiency, it is recommended to adopt a rounded corner design to enable the CNC machine tool to operate continuously and reduce pause time.
9.Avoid thin-wall processing
Thin-walled parts are extremely susceptible to damage during CNC machining and require special care. To avoid breakage due to machining forces or vibration, CNC machines need to cut at low speeds, adding time and cost. Although using thicker walls instead of thin walls may slightly increase material costs, it can significantly reduce CNC machining costs.
10.Choose a reliable manufacturer
There are many CNC machining companies, but the quality varies. Quality manufacturers may not necessarily have the lowest prices, but they will provide the best value for money and results. Some manufacturers attract customers with low prices but sacrifice operational quality. To avoid such pitfalls, it is recommended to look for a reliable manufacturer that offers the required quality and price.
Why choose Longsheng as your CNC machining manufacturer?
Longsheng provides one of the best CNC machining services for a variety of applications. We are one of the world’s leading parts manufacturers with expertise in CNC milling, CNC turning, CNC drilling, precision machining and other services.
With Longson you can find a one-stop solution for all your manufacturing needs, whether you need CNC machining services for prototyping, production or rework, we are here to help. With our expertise and industry-leading technology, we can provide you with the highest quality online CNC parts and the best CNC machining services. Our high-quality manufacturing process is extremely fast and uses the most advanced CNC machinery in the world. Delivery times can be as fast as three days.
Conclusion
The hidden cost in CNC machining is an important part that cannot be ignored in enterprise cost control and management. In order to reduce hidden costs, companies need to take a series of measures, such as optimizing resource allocation, improving tool quality, strengthening risk management, shaping a healthy corporate culture, optimizing manufacturing processes and communication methods, improving credit status, and strengthening entrepreneurs’ own capacity building. Through the implementation of these measures, enterprises can not only reduce hidden costs, but also improve production efficiency, product quality and market competitiveness, thereby achieving sustainable development.
Contact us now to get exclusive customized CNC machining solutions!
📞 Phone: +86 185 6675 9667
📧 Email: info@longshengmfg.com
🌐 Website: https://www.longshengmfg.com/
Disclaimer
The content appearing on this webpage is for informational purposes only. LongSheng makes no representation or warranty of any kind, be it expressed or implied, as to the accuracy, completeness, or validity of the information. Any performance parameters, geometric tolerances, specific design features, quality and types of materials, or processes should not be inferred to represent what will be delivered by third-party suppliers or manufacturers through LongSheng’s network. Buyers seeking quotes for parts are responsible for defining the specific requirements for those parts. Please contact to our for more information.
Team LongSheng
This article was written by various LongSheng contributors. LongSheng is a leading resource on manufacturing with CNC machining, sheet metal fabrication, 3D printing, injection molding,metal stamping and more.
FAQs
What are the hidden costs?
Implicit costs refer to the part of the cost actually borne by the enterprise itself in addition to explicit costs (such as direct costs such as raw materials, labor, equipment, etc.) during the production and operation process. These costs are not directly reflected in the financial statements, but they do have an impact on the company’s operations and profits. Implicit costs include but are not limited to time costs, management costs, risk costs, opportunity costs, etc. In CNC machining, hidden costs may include rapid wear of tools, idle equipment, inefficient production processes, rework due to substandard quality, etc.
Why is CNC machining expensive?
Reasons for the high cost of CNC machining: High-precision requirements require high-quality equipment, cutting tools, and professionals; complex customized designs increase equipment purchase and maintenance costs; high-performance special materials increase costs; professional technicians operate and program to increase labor and technology costs; indirect costs such as equipment depreciation, management, and quality control also affect the total cost.
How much does a CNC machined part cost?
The cost of a CNC machined part varies depending on a variety of factors, including but not limited to the part’s size, shape, material, quantity, accuracy requirements, processing time, etc. Therefore, a specific cost figure cannot be given. In actual operations, companies usually need to make estimates based on specific processing needs and conditions, combined with market prices and internal costs.
How is CNC machining cost calculated?
CNC machining cost calculation involves: material cost (depending on part size, shape, material); labor cost (including programming, operation, monitoring, inspection, based on processing time, technician salary and quantity); equipment cost (acquisition, depreciation, maintenance, allocated to each part); tool cost (determined by type, quantity, life, replacement frequency); indirect costs (management, quality control, water, electricity, facilities, etc., allocated based on the number of parts or time).
