The primary difference is the orientation of the spindle. Vertical mills are more common and versatile for most jobs, while horizontal mills are better suited for heavy, large parts and high-volume production due to superior chip evacuation.

While the hourly rate is higher, 5-axis milling can machine a complex part in a single setup. This eliminates the time and potential for error associated with multiple setups on a 3-axis machine, often resulting in a lower total cost.

Aluminum alloys like 6061 and 7075 are excellent for high-speed milling due to their good machinability and thermal conductivity. Softer plastics and brass also perform very well with high-speed toolpaths.

We use several strategies, including specialized low-stress fixturing, sharp cutting tools designed for plastics, and optimized toolpaths with high feed rates and low depths of cut to minimize heat buildup and prevent warping.

Climb milling cuts in the same direction the tool is rotating, producing a better surface finish and longer tool life. We primarily use climb milling, but may use conventional milling in specific situations to control part deflection.

 Yes. After milling, we use a multi-stage vapor polishing or buffing process to achieve a fully transparent, optically clear finish on acrylic and polycarbonate parts.

In addition to a 3D CAD file, material, and quantity, a 2D drawing highlighting the critical features and tolerances is extremely helpful for 5-axis work. This ensures we focus on what matters most to your design.

A general rule of thumb is that the depth of a pocket should not exceed 4-6 times the diameter of the cutting tool. For deeper pockets, we may need to use specialized long-reach tools, which can impact cost.

Common mistakes include designing sharp internal corners (always add a radius), unnecessarily tight tolerances, and very thin walls. Our DFM feedback will help you identify and correct these issues.

We recommend designing with a corner radius of at least 1/8" (3mm) to allow for the use of robust standard tooling. Smaller radii are possible but will increase machining time and cost.

Yes, we use a process called thread milling to create highly accurate internal and external threads of various sizes. This is often more precise than tapping for critical applications.

For large parts, we use temperature-controlled environments, in-process probing to check dimensions during machining, and stress-relieving procedures for materials prone to warping. Final inspection is done on our large-format CMMs.

A fixture is a custom work-holding device designed to securely hold a part during milling. Proper fixture design is critical for accuracy, repeatability, and preventing part damage, especially for complex or delicate components.

Yes, we work with certified partners to provide a wide range of heat treatment services for steel alloys. This includes hardening, tempering, and annealing to achieve the desired mechanical properties after milling.