In today’s competitive manufacturing industry, efficiency and cost-effectiveness are vital factors that can significantly impact a company’s bottom line. One of the primary issues seen by precision machine companies is the tendency of outside engineers to over-engineer tolerances. When using design software it typically defaults to tolerances that go out to the three-decimal point range. While this may seem like a cautious approach, it can result in wasted material and increased expenses, adding unnecessary costs during the machining process.
Below, we explain when high-precision machining tolerances are necessary and how our in-house Design for Manufacturing and Assembly (DFMA) services can improve existing parts and save money without sacrificing quality, strength, or precision. The goal is to work together to find machining solutions for every application.
Staub’s In-House Engineering Solutions
Staub Precision Machine offers advanced in-house Design for Manufacture and Assembly (DFMA) services to address the challenge of engineering efficiency. By collaborating with customers during the design process, Staub can identify potential design issues and suggest improvements that enhance efficiency and reduce costs. This collaborative approach ensures that engineering efficiency is prioritized from the initial stages, resulting in cost-effective production processes and high-quality parts.
As a trusted partner, we go beyond traditional machining processes and challenge conventional design approaches. Our goal is to maximize efficiency, improve overall product design, and optimize manufacturing processes to achieve quicker time to market, reduced errors or faults, and higher-quality end products. Our commitment to DFMA empowers our customers to unlock significant cost savings while maintaining exceptional quality and performance.
When Are High-Precision Machining Tolerances Necessary?
High-precision machining tolerances are essential in certain industries where components must fit into complex assemblies perfectly. The slightest deviation from the specified tolerances can lead to significant consequences, ranging from compromised functionality to catastrophic failures.
In these industries, where precision is not just a preference but a necessity, high-precision machining tolerances are indispensable. Manufacturers must employ advanced machining techniques, state-of-the-art equipment, and skilled technicians to achieve tolerances. By prioritizing precision, these industries can deliver reliable, safe, and high-performance products that meet the exacting standards of complex assemblies.
Applications for which high-precision machining tolerances are most needed include:
- Aerospace: Airplanes and spacecraft require parts made with high-precision machining tolerances that are tighter than standard ones to ensure the reliability of airplane engines, navigation systems, rockets, and an array of structural components.
- Automotive After Market: Certain components require high precision machining tolerances within +/- 0.001 inch (0.0254 mm) to ensure the vehicles in which they’re installed operate efficiently and reliably, which includes those used in carburetors, engines, exhausts, fluid systems, and suspensions.
- Medical Devices: Whether for diagnostics or surgery, medical equipment used both internally and externally requires sufficiently high precision; machining tolerances need to be particularly tight for diagnostic equipment like ultrasound machines, MRI scanners, heart rate monitors, and biopsy tubes as well as for those utilized in surgical procedures like clamps, forceps, medical implants, and surgical scissors.
- Military: For an array of military applications that include communication equipment, drones, military aircraft and vehicles, missile defense, and targeting systems, defense contractors require components made with high-precision machining; tolerances are critical for dependable and optimal performance, especially when this equipment is deployed to conflict zones.
- Optical: For optical equipment like mirrors, lenses, or interferometers, tight tolerances are often necessary with precision machined components to ensure images aren’t distorted or signals aren’t lost.
Tolerances for custom parts, equipment used in research, scientific instruments, and other critical applications must be extraordinarily accurate. This is due not just to the reliability of the end product but also to the safety of those who use it, as is the case in the aerospace, automotive, defense, and medical device industries.
The Staub Difference & High-Precision Machining
In the ever-evolving manufacturing landscape, companies need forward-thinking partners like Staub Precision Machine to help navigate design challenges, improve efficiency, and enhance their competitive edge. With nearly 20 years of experience in DFMA, customers can trust that their engineering processes will be streamlined, resulting in significant cost savings without compromising on quality or precision. We encourage design collaboration with our in-house engineers to find ways to improve upon high-tolerance precision components while making manufacturing processes more efficient. To learn more about how we can keep costs down for your high-precision machining project, contact the CNC machining experts at Staub today.