A Case Study in 5-Axis Machining: Reducing Setups and Improving Lead Times

At Focused on Machining, our 5-axis machining is now running at full speed. As our team has gained experience with the new equipment, we have become more efficient in our manufacturing for 5-axis parts. 

5-axis machining is often associated with complex geometries, and it does allow us to machine challenging contours and other difficult features more effectively than many traditional setups. But in our shop, customers have also seen major benefits in speed, as well.

One recent manifold project is a strong example of how 5-axis machining can improve efficiency and help keep demanding jobs on schedule. 

A Complex Manifold With Tight Requirements

Focused on Machining has produced complex manifolds for years, and this recent project was an excellent example of the precision machining work we often do. The part was an aluminum block measuring roughly 2 inches by 2 inches by 12 inches, with 17 ports.

This manifold was part of our aerospace machining work for a customer. It was designed for fuel lines in a rocket engine, so positional accuracy was critical and the tolerance requirements on the holes were extremely tight. In fact, inspection did not stop at the physical surface of the part. We also had to project a feature location four inches out from the part and verify that it still met the required positional tolerance at that distance.

Before and After: Reduced Setups, Greater Efficiency

We originally quoted and planned this part before our 5-axis machine arrived, and at that point, we planned for the part on our existing equipment. Ultimately, though, we were able to machine it on our new 5-axis. That gives us a clear before-and-after comparison:

• If we had machined this manifold on our horizontal machine, it would have required four operations. 

• On a vertical machine, it would have taken at least seven operations. 

• On our 5-axis machine, we completed it in just two operations.

How Reduced Operations Benefit Customers

For those who aren’t in a machine shop every day, it’s worth explaining what these terms mean. An “operation” is essentially a separate setup or machining step. Each time a part has to be repositioned or moved so a different side or feature can be machined, that adds another operation.

Fewer operations benefit customers in multiple ways. First, every time a part is handled in a setup, it introduces the opportunity for error. Second, each additional setup adds labor and production time because the part must be reoriented and verified before machining continues. Third, longer cycle times within fewer setups can create opportunities for unattended lights-out machining, which can significantly improve throughput.

Lights-Out Manufacturing Led to Scheduling Flexibility

This job also involved substantial outside processing that we coordinated on the customer’s behalf, including chem film and precision cleaning. Because of those requirements, we had very little room for delay during machining.

Fortunately, the reduced number of setups made a major difference. Cycle times were nearly three hours, and the 5-axis machine is palletized, which allowed us to load multiple parts at once. Those factors let us run these parts for approximately six hours unattended at night. As a result, we kept the project moving and met its deadline.

Always Getting Better, Faster, and More Cost-Efficient

Our experience with 5-axis machining is leading to consistent improvements in efficiency. We’re already seeing shorter production times, and we expect the trend to continue. And over time, we know increased efficiency will help reduce costs for customers in our contract manufacturing services.

If you have a part that could benefit from 5-axis machining, let’s discuss. Whether the priority is part complexity or shorter lead times, Focused on Machining is ready to help. Contact us today!

Reliable 5-Axis Machining Services for Prime Contractors

At Focused on Machining, our 5-axis machining services and advanced scheduling allow us to expertly support prime contractors. We take on-time delivery performance seriously as your manufacturing partner because we know one late supplier can derail an entire production line. Currently, our on-time delivery rating sits at 95%. 

Our 5-axis machining enables us to machine complex parts and serves as part of a larger system designed to reduce your risk and compress timelines.

5-Axis Machining: Complex Parts With Less Risk

5-axis machining is well known for handling complex geometry and features, but consistency is just as important for prime contractors. After all, many complex parts can be produced on 3-axis equipment, but the 3-axis option requires more setups and fixturing, introducing more chances for error.

Consider a part with multiple datums and a tight-tolerance hole that has to be located precisely relative to all of them. 3-axis equipment can achieve that result, but it depends on an expert machinist perfectly executing several flawless setups. Every additional setup introduces new risk.

With 5-axis machining, that same job can be completed in a single setup. Fewer setups mean better positional accuracy and a more repeatable process. That, in turn, will lead to fewer surprises during inspection and an overall more stable production and precision machining process.

Speed Scales With Automation

Speed is important in every industry, but for prime contractors, the large programs they often manage can make speed and reliability critical. Instead of waiting for a single order, you’re keeping a huge number of tasks on track. 

Our five-axis not only reduces setup time, but it allows for extended runtime and lights-out operation, as well. That efficiency helps us protect lead times even when schedules get tight. The additional capacity also helps us adjust when the unexpected occurs, preventing disruption for your project and making us a perfect partner for contract manufacturing services.

A Process for Reliability in Every Step

When machine shops struggle with late deliveries, it’s rarely from any single mistake. Instead, they come from systemic process issues: no buffer for uncertainty, limited visibility in a schedule, and no technology to help recover from setbacks. If shops can’t recognize a problem until the due date arrives, you might be facing weeks or months until delivery.

We never want to put a customer in that position at Focused on Machining. We build realistic schedules in ProShop to account for not only the full scope of work but the inevitable bumps that happen in production. The scheduling is updated dynamically, allowing us to spot risks early and communicate with you to find solutions.

Our 95% on-time delivery rating does mean that a small percentage of our jobs ship late, but our process almost always allows us to measure those delays in days, not months. In part, that’s due to the modern equipment, like 5-axis machining, that we’re able to pair with our transparent scheduling technology.

Complexity and Dependability In One Shop

Prime contractors need dependable delivery just as much as they need complex parts, and we’re ready to provide both in our 5-axis machining services. Contact us today and partner with our Colorado machine shop for a low-risk manufacturing partner!