5 axis Routing

5-axis routing is an advanced machining process used in manufacturing to produce complex and highly precise parts. Unlike traditional 3-axis routing, which operates along the X, Y, and Z axes, 5-axis routing adds two additional rotational axes, usually denoted as A and B. This capability allows the cutting tool to approach the material from virtually any angle, offering unprecedented flexibility and precision.

With 5-axis routing, manufacturers can create intricate designs, curved surfaces, and complex geometries that would be challenging or impossible with conventional methods. This technique is particularly valuable in industries like aerospace, automotive, and mold-making, where accuracy and the ability to handle complex shapes are critical.

Additionally, 5-axis routing reduces the need for multiple setups and repositioning, enhancing efficiency and consistency. By integrating this technology, businesses can achieve higher-quality results, streamline production processes, and push the boundaries of design innovation.

Who uses 5 axis routing?

5-axis routing is utilized across various industries where precision, complexity, and efficiency are critical. Here’s a look at who uses it and why:

1. Aerospace Industry: Aerospace manufacturers use 5-axis routing to produce intricate components like turbine blades, structural parts, and engine housings. The ability to machine complex geometries with high accuracy ensures that parts meet stringent performance and safety standards.

2. Automotive Industry: In automotive manufacturing, 5-axis routing is employed to create complex engine components, custom parts, and molds for high-performance vehicles. The technology’s precision helps in achieving tighter tolerances and better surface finishes, essential for high-quality production.

3. Medical Device Manufacturing: Medical device manufacturers rely on 5-axis routing to produce complex, precise components such as surgical instruments, implants, and prosthetics. The technology allows for the detailed work needed to meet rigorous health and safety regulations.

4. Mold and Tool Making: In mold making, 5-axis routing is used to create intricate and highly detailed molds for plastic and metal parts. The ability to machine complex shapes in a single setup improves accuracy and reduces production time.

5. Aerospace and Defense: For defense and aerospace applications, where custom, high-precision parts are often required, 5-axis routing provides the necessary flexibility and precision to meet exacting specifications and handle advanced materials.

6. Custom and Prototype Work: Companies involved in custom fabrication or prototyping use 5-axis routing to create unique parts and models with complex geometries. The ability to rapidly produce and refine designs is crucial in these fields.

Benefits of using 5 axis Routing

Using 5-axis routing offers several key advantages that can significantly benefit manufacturing and design processes:

1. Enhanced Precision: The additional rotational axes allow for more precise control over the cutting tool, enabling the creation of complex shapes and intricate details with high accuracy.

2. Complex Geometries: 5-axis routing can handle more complex geometries and contours than traditional 3-axis machines, making it ideal for parts with intricate designs or curved surfaces.

3. Reduced Setup Time: With the ability to machine multiple sides of a part in a single setup, 5-axis routing minimizes the need for repositioning and multiple setups, saving time and reducing the potential for errors.

4. Improved Efficiency: The ability to cut from various angles means fewer tool changes and shorter machining cycles, leading to increased overall productivity.

5. Higher Quality Finish: The precise control offered by 5-axis routing often results in a smoother surface finish and better overall part quality.

6. Design Flexibility: This technology enables designers to push the boundaries of creativity, allowing for more innovative and complex designs that would be challenging or impossible with traditional methods.

What materials can you cut?

Polyurethane model boards and foams

 The most common material we put through our 5 axis router, the range of densities ensure there is a material to suit your product that combines accuracy, speed of machining and strength. Boards range in size and thickness but we can design material billets in 3D CAD to minimise waste, CNC cut the blocks and bond them up using special paste that matches the board density. This way we use the minimum of what is sometimes a very expensive parts of the job. Densities range from 0.08kg/m3 to 1.86kg/m3

Epoxy tooling boards

As with polyurethane boards there is a large range of densities to choose from. They are very heat resistant and have a very fine surface structure. This makes them ideal as moulds and tools for composites. These properties are important both as prepreg master pattern and for direct tooling or high-frequency welding. As dimensionally stable hard plastic boards, epoxy tooling boards can be precisely tailored to the requirements of the respective applications.

Densities range from 0.08kg/m3 to 1.86kg/m3

Expanded & Extruded Polystyrene (EPS)

Expanded & Extruded Polystyrene’s are available in a range of different densities ( 10 – 40kg/m3 ) . A light weight cost effective packaging & insulation material used across a wide range of industries and packaging applications. Available in sizes up to 2500mm x 1250mm x 640mm, it also makes a very good material for sculpting and can be shaped to most designs where there is no this geometry. Often EPS is used for sculptures prior to being coated in plastic or clay.

Soft and Hardwoods

We can source, cut and machine a variety of soft and hardwoods and specialise in complicated three dimensional shaping of woods. Our knowledge of this area allows us to produce almost any shape in wood.

MDF and Plywood

Using our 3D CAD software we can slice up your CAD model, translate the layers to 2D CAD and cut them in MDF or Plywood before bonding them back together to create a cheaper alternative to foam boards. This hels to keep material wastage to a minimum and reduces the machine time on the 5 axis keep costs lower. And its surprising how good a finish you can get on MDF and plywood!

How big is your machine?

The bed size on our 5 axis machine allows parts up to 3500mm x 2000mm and 1000mm in height. However its no that often we machine parts this big as it makes more sense to break models down into more manageable sections before machining.

What files can you work with?

We are able to machine from just about any three dimensional file type including point cloud data (STL). Sometimes we may have to make some changes to the CAD in order to machine from it, such as filling gaps and closing shapes. This will be included in the quote if required.