Predating CNC machines, automated processes, and 3D printing, manual machining was the standard method for producing physical goods, dating back to Egypt, Greece, and Rome. The Egyptian bow lathe exemplifies an early machining tool, requiring one person to rotate the workpiece using a bow-shaped tool while another person carved it with hand tools.
Today, machining processes have evolved significantly, often requiring minimal operator intervention beyond pressing the “GO” button. Advances in technology allow us to create high-fidelity prototypes with complex geometries in half the time. So, why should a modern design studio maintain in-house manual machining capabilities? What is the value for today’s engineers?
After completing a manual machining project to refine our skills and consulting with our Smart Design engineers with manufacturing experience, we were able to address these questions. This is what we learned.
Although 3D printing processes such as FDM and SLA are typical go to for majority of rapid prototyping, manual machining still plays a crucial role in that process. If a prototype needs to be changed, manual machining can be used to modify it. 3D printing has its limitations, such as high tolerances, uneven surface finishes, and potential warping or shrinking of parts. These issues can affect how designs perform in reality. To achieve more accurate and reliable parts, supplementing 3D printed components with simple machining techniques is often necessary for evaluating design feasibility.
Whether consulting for client work, or in-house product development teams, pace is an important factor to consider. The timeline for fabricating prototype parts can range from a few days to several weeks depending on the process, materials, complexity, and quantity. Sometimes manual machining allows engineers to get to a viable solution more quickly. Similarly, if you do fabricate parts, and issues arise, it can be more time consuming and costly to refine the design and order a new batch of prototypes. Having the manual machining tools and skills readily available, allows for precise in-house modifications in a shorter timeframe that still maintain the original design’s integrity and fidelity.
Learning machining processes serves as a tool for engineers – it develops practical skills and fosters a thorough comprehension of the process. Manually machining parts provides a hands-on approach that fosters a deeper understanding of material properties and part interactions, which can be invaluable for one’s expertise. At Smart, a lot of projects revolve around injection molding where machining is still the primary method for making molds. With manual machining training, our engineers understand process limitations early on, resulting in higher output quality, and decreasing the need for rework. This efficiency benefits our clients and leads better refined and well-tested products.
Although the globalization of product development and manufacturing offers numerous benefits, it often results in fewer opportunities for US-based engineers to gain first-hand experience with manufacturing processes. This challenge was intensified by the pandemic, which restricted travel and further limited exposure. For younger engineers and designers, this often means steeper on-the-job learning curves. Coupled with a lack of hands-on experience, this can result in lower confidence, affecting both career and personal growth. At Smart, we counteract this challenge by providing engineers with access to various manufacturing processes. Our engineers can use the available machines at any time and even work on personal projects. This hands-on exposure not only enhances their skill set but also significantly boosts their confidence. Knowing they have firsthand experience with the processes involved gives them a solid foundation as they approach projects.
While manual machining equipment may seem outdated in a modern design studio, it remains a valuable tool for rapid prototyping, reducing project lead times, and training engineers. It fosters hands-on problem-solving and builds confidence in early-career engineers. Maintaining these capabilities not only ensures adaptability in tackling unexpected challenges but also cultivates a versatile team that balances traditional craftsmanship with modern innovation.