DESIGN GUIDE >> CNC MACHINING

Quotes in Hours. Parts in Days.

rapidmanufacturing.com
DESIGN GUIDE >> CNC MACHINING

Contents
03 Overview FINISHING
03 Capabilities 12 Threads
03 Certifications & Registrations
13 Metal Finishes
04 Stock Materials
14 Powder Coating & Silk Screening

DESIGN GUIDELINES RESOURCES

04 Tolerances 15 Resources

05 Wall Thickness

06 Outside Corners

07 Hole Depth

08 Interior Fillets

09 Floor Fillets

10 Mating Parts

11 Undercuts

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 DESIGN GUIDE >> CNC MACHINING

We launched CNC machining at Rapid in 2009 to satisfy customer

demand for machined prototypes. We use 3D CAD data to streamline
the quoting and manufacturing process, which accelerates your
turnaround time.

This guide discusses machining best practices and tips to ensure

your machined part is designed for durability, manufacturability,
and end-use applications.

CAPABILITIES

PART SIZE:
Vertical Milling: <38 in. x 24 in. XY footprint
Turning: <12 in. diameter, 18 in. length

IN-HOUSE CAPABILITIES:
• Vertical CNC Milling • Drilling • Tumbling
• CNC Turning on Lathe • Tapping • Powder Coating
• Assembly • Threading • Silk Screening
• Knurling • Bead Blasting • Plating
• Welding

CERTIFICATIONS AND REGISTRATIONS

• ITAR Registered
• ISO 9001:2015
• AS9100Dz
• RoHS Compliant

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 DESIGN GUIDE >> CNC MACHINING

STOCK MATERIALS

METAL
• Aluminum 6061
• Aluminum 7075
• Stainless Steel
• Carbon Steel
• Tool Steel
• Brass
• Copper

PLASTIC
• ABS
• PVC
• Radel
• Acetel (Delrin)
• Polycarbonate

Full selection available online at rapidmanufacturing.com

TOLERANCES

We use a standard tolerance of +/- 0.005 in. for metal parts and plastic parts unless otherwise specified by
the customer.

NOTE: We are capable of manufacturing

to tighter tolerances. If this is required, it
may increase both lead time and cost due
to potential additional steps during the
manufacturing process.

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 DESIGN GUIDE >> CNC MACHINING

WALL THICKNESS

The wall thickness should be greater than 0.060 in. If walls are too thin, the part can distort and warp, especially if
using a plastic material.

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 DESIGN GUIDE >> CNC MACHINING

OUTSIDE CORNERS

Designing parts with an outside radius can be expensive and time consuming to manufacture. Parts that require
this feature use both a very precise set-up and form-relieved cutter to achieve the shape. To avoid this additional
cost, design parts with chamfers. A chamfer is a symmetrical sloping surface on a corner.

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 DESIGN GUIDE >> CNC MACHINING

HOLE DEPTH

When designing a part, holes should have a depth less than four times the hole diameter. This will prevent end-mill
chatter which creates an uneven or blemished surface.

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 DESIGN GUIDE >> CNC MACHINING

INTERIOR FILLETS
Designers and engineers creating parts for vertical or horizontal milling should consider areas where a radius will
occur. When designing a part with an inside corner radius, a non-standard radius, slightly larger than a standard
radius, should be used. By designing a part with a larger non–standard radius the milling tool is able to continue
milling as it traces the corner. The ability to continue milling prevents the machine from slowing down, which can
create chatter marks due to vibration.

QUICK TIP
Looking to save costs?
The larger the radius,
the larger tool and less
machine time to remove
material saving both time
and money.

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 DESIGN GUIDE >> CNC MACHINING

FLOOR FILLETS
CAD systems have a short cut for designers, and with a few clicks in your design program, the floor radius and wall
radius are the same. These parts are difficult to mill and can be expensive if multiple tools are required to remove
the material. For a clean, smooth corner it is recommended to make the floor radius smaller than the corner radius.

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 DESIGN GUIDE >> CNC MACHINING

MATING PARTS
Parts being designed to fit together should have the corners of the pocket cut away with an end mill. This will allow
the mating part with sharp corners to fit without alignment issues.

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 DESIGN GUIDE >> CNC MACHINING

UNDERCUTS
Undercuts result when a machine cutting tool cannot reach a designed feature and should be avoided as they add
cost and possibly lead-time to production. The reasons undercuts can be costly is the requirement of a special tool
and programming that can slow cutting speeds for the feature.

Undercuts require custom tools when they are not a standard dimension. The requirement of a custom tool can
both increase the cost and lead time for the part.

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 DESIGN GUIDE >> CNC MACHINING

THREADS
There are several ways to manufacture threads including cut taps, form taps, and thread mills. When designing
parts with threads it is recommended to use the largest thread size possible. We require a three-thread lead
minimum. There is no depth maximum, but threaded holes should only be as deep as necessary. If thread holes are
deeper than standard tooling, a custom tool will need to be ordered and lead time and cost will increase.

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 DESIGN GUIDE >> CNC MACHINING

METAL FINISHES

Standard This finish is how the part looks after it is machined. Toolmarks will be visible.

Bead Blast This matte finish is created by glass beads blowing against the parts.

This finish creates a corrosion and water resistant surface. We offer clear, black, blue,
Anodize
green, and red colors with or without masking. (Type I, II, & III)

This finish is used on metals as a primer, corrosion inhibitor, or to retain

Chromate
electrical conductivity.

Etch This creates a dull, rough finish because the process removes a layer of steel.

Nickel This finish adds nickel lacquer to a part for either a dull or shiny finish.

Passivate This finish is a light layer of protective material applied to a part to prevent corrosion.

This is a hard ceramic material finish that is used to improve the surface properties of a
Tin
part and add a conductive finish.

This protective finish is applied to parts that are susceptible to aggressive wear-and-tear
Zinc and corrosion. Color options include black, blue, clear, phosphate, yellow, and
yellow (RoHS).

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 DESIGN GUIDE >> CNC MACHINING

POWDER COATING AND SILK SCREENING

We offer in-house powder coating and silk screening. We are ITAR registered and powder coat or silk screen parts in
compliance with government regulations. In addition, we can order any other powder needed, but it will extend lead
times. Silk screen colors can be matched to any Pantone number provided and all inks are stocked in-house.

Tiger Drylac Tiger Drylac Tiger Drylac

89/71530 49/42310 49/00530
Light Gray Dark Blue Sky Blue
Textured RAL 5013 RAL 5015
RAL 7035

Tiger Drylac Tiger Drylac Tiger Drylac

49/72020 49/22580 089/41050
Telegray 4 Signal Yellow Azure Blue
RAL 7047 RAL 1003 Textured
RAL 5009

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 DESIGN GUIDE >> CNC MACHINING

RESOURCES
myRAPID: myRAPID is the Rapid customer portal. It allows you to quote multiple files at once (instantly quoting
sheet metal parts), see past quotes, update contact and shipping information, and order multiple parts.

VISIT: rapidmanufacturing.com/myRAPID

RAPIDQuote: Upload 3D CAD files and our team of engineers will process your request and send a quote
out within 24 hours.

VISIT: quote.rapidmanufacturing.com

Powder Coat Library: See our list of stocked powders at rapidmanufacturing.com/powdercoat

Machined Part Design for Manufacturing, LinkedIn Group: This group is for
engineers who design machined parts. It provides them with an online forum to collaborate and discuss
techniques to better design machined parts for manufacturability.

JOIN: linkedin.com/groups/8531417

World Headquarters Rapid, a Protolabs Company rapidmanufacturing.com

5540 Pioneer Creek Drive 15 Charron Avenue protolabs.com
Maple Plain, MN 55359 Nashua, NH 03063 603-595-1400