Don't let over-engineering kill your budget. Learn how Chinese smart factories optimize your CAD files for maximum savings without sacrificing quality.
The price of a machined part isn't random. It's a direct result of three factors: Material Cost, Machine Run Time, and Setup Time. While you can't control the market price of aluminum, you *can* control how long your part takes to machine.
At InstaMfg, we process thousands of prototypes monthly. The data shows that 70% of cost drivers are locked in during the design phase. Here is how to optimize your designs for our China-based CNC centers.
01. Radius Geometry & Internal Corners
CNC tools are round and rotate. They cannot cut a perfectly sharp internal corner. Requesting a sharp 90° internal corner forces us to use EDM (Electrical Discharge Machining), which can triple the cost.
💡 The Pro Tip:
Add a radius to all internal corners of at least 1/3 the depth of the pocket. This allows us to use larger, stiffer tools that remove material faster, reducing run time.
02. Standardize Your Tolerances
Tight tolerances (±0.005mm) require slower feed rates, specialized inspections, and higher scrap rates. Do not apply tight tolerances to every surface.
- Standard: ISO 2768-m (±0.1mm) is free and standard at InstaMfg.
- Precision: Only apply critical tolerances (H7, ±0.01mm) to mating surfaces or bearing bores.
- Loose: For cosmetic surfaces, standard tolerances are sufficient.
03. Understanding the Cost Breakdown
Where does your money go? We analyzed the cost structure of a typical medium-complexity aluminum enclosure produced in our factory.
Machining time (Run Time) is usually the biggest cost driver. Simplifying geometry to reduce runtime has the highest ROI.
Note: "Setup" costs are high for 1 unit but vanish at 100+ units.
04. Material Selection Matters
Just because Titanium is stronger doesn't mean your prototype needs it. Harder materials destroy tools faster and take longer to cut.
| Material | Machinability | Cost Index |
|---|---|---|
| Aluminum 6061 | Excellent | $$ (Baseline) |
| Stainless 304 | Hard | $$$ (+150%) |
| Titanium Gr5 | Difficult | $$$$$ (+400%) |
05. Leverage the Volume Curve
CNC machining has high startup costs (CAM programming + Fixturing). If you order 1 part, you pay 100% of that setup. If you order 50 parts, that cost is split 50 ways.
At InstaMfg, our AI quoting engine automatically suggests volume break-points. Often, ordering 10 parts costs only marginally more than ordering 5.
Ready for a competitive quote?
Send us your optimized designs and experience the InstaMfg price advantage.
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