Machining / High-mix, low-volume
Precision machining (high-mix, low-volume)
Precision machining is the cutting of metal or plastic on machining centers and CNC lathes to make parts to tight tolerances of about ±0.005 to 0.025 mm. In high-mix, low-volume production, each drawing is set up individually, from a single prototype to a few hundred pieces.
How it works
"Why it works"The basic methods are milling, where the tool rotates (machining centers), and turning, where the workpiece rotates (CNC lathes). Five-axis machining centers can produce complex shapes in fewer setups.
Accuracy depends on the machine, tooling, fixtures, temperature control and measurement together. Results are verified with inspection equipment such as coordinate measuring machines.
In high-mix, low-volume work, programming (CAM), setup and fixture design drive lead time and cost. The sooner the drawing, material, quantity and tolerances are fixed, the more accurate the quote.
Main effects
- Complex shapes can be machined from a single piece
- No tooling or molds required, which suits prototypes and small lots
- Wide choice of materials, from metals to plastics
- Tolerances and surface roughness can be specified on the drawing
Definitions
- Tolerance
- The permitted variation of a dimension. ±0.01 mm means anything within 0.01 mm above or below the nominal size is accepted.
- 5-axis machining
- Machining controlled on five axes: three linear and two rotary. Complex shapes can be machined in fewer setups.
- High-mix, low-volume
- A production mode with many different items and small quantities of each, often from prototypes up to a few hundred pieces.
Applications
"Where it is used"| Field | Examples |
|---|---|
| Semiconductor equipment and industrial machinery | Mechanism parts and fixtures inside equipment |
| Medical devices | Parts for instruments and equipment |
| Robotics | Arm and joint components |
| R&D | Prototypes and test parts |
Typical process conditions
"Under what conditions"These are general guides. Actual conditions are set by the supplier for each part, material and specification.
| Item | Typical |
|---|---|
| Tolerance (standard) | ±0.025–0.1 mm |
| Tolerance (precision) | ±0.005–0.025 mm |
| Tolerance (ultra-precision) | ±0.003 mm or tighter |
| Surface roughness | About Ra 0.8–3.2 μm for typical machined finishes |
| Lot size | 1 piece (prototype) to a few hundred |
| Materials | Aluminum alloys, carbon steel, stainless steel, titanium, engineering plastics, etc. |
| Information needed to order | Drawing (2D/3D data), material, quantity, tolerances, surface treatment, desired delivery date |
FAQ
"Direct answers"Can I order without a drawing?
Some suppliers offer design support and can create drawings from a sample or sketch, but please provide drawings (3D data) wherever possible for an accurate quote and lead time.
Why is the unit price higher for small lots?
Programming and setup costs are incurred regardless of quantity, so the smaller the lot, the larger the share per piece.
Can I order from overseas with English drawings?
Some suppliers accept English inquiries and English drawings. Check each company's overseas support in the supplier list.
Which companies in Japan offer Precision machining?
Among the companies listed on FactoryMatch, HEPHAIST Co., Ltd., Kaiwa Co., Ltd., Kinki Blade Industries Ltd., Miyajima Co., Ltd. offer Precision machining (based on each company's published information). See the supplier comparison table for minimum lots and overseas support.
Suppliers
"Who to ask"Based on the listed companies' published information.
| Company | Location | Relevant technology | Minimum lot | Overseas support |
|---|---|---|---|---|
| HEPHAIST Co., Ltd. | Kawagoe, Saitama | Grinding | — | Export experience, Wholly owned subsidiary in Shanghai, China (赫菲（上海）軸承商貿有限公司) and a production site in Suzhou. Most overseas sales are exports denominated in foreign currencies. The official website has English and Chinese versions; exhibits at overseas trade shows in Shanghai, Shenzhen and elsewhere |
| Kaiwa Co., Ltd. | Uenohara, Yamanashi | Milling / Machining center | Prototype | — |
| Kinki Blade Industries Ltd. | Moriguchi, Osaka | Grinding | — | The official website has an English page |
| Miyajima Co., Ltd. | Taga, Shiga | Turning / Lathe | — | — |