Precision Machining for 3D Printed Metal Parts and Additive Components

At KT Tech, we take on many different types of challenging projects like micropart machining and low-volume Swiss machining. Our team is used to working on parts that have no room for error.

Machining 3D printed metal parts requires the same level of focus. These parts often arrive at our shop after significant time and resources have already been invested in the additive manufacturing process, so preventing scrap is critical. Learn how we’ve adopted the right equipment and processes to successfully machine additive components.

Why 3D Printed Metal Parts Still Need Machining

Metal 3D printing has made impressive progress in recent years, and it serves many important use cases. We frequently see additive manufacturing parts with complex geometries that would be extremely difficult or impossible to create with conventional machining by itself.

However, metal 3D printing does not always provide the final precision required for certain critical features. CNC machining may be required to bring the part to its final form, and KT Tech is ready to help.

Starting With Advanced CAM Simulation

Our process starts with top-tier CAM software, hyperMILL. Before any cutting begins, we use the software to perform virtual machining simulations and verify the full machining process.

For these projects, mistakes on the physical part are not acceptable. A virtual version of the machine setup lets us verify the process before a part enters a machine. We can confirm that tool paths are safe and there will be no unexpected movements.

Experience With Proven Machining Strategies

The success of our process also stems from our experience. Over time, we have standardized many aspects of our machining process, including tooling, feeds, speeds, and stepovers.

We rely on proven and validated strategies that we know are reliable, and we adhere to those on our customers’ valuable 3D printed components. Our consistency reduces variables and minimizes the risk of nonconformance.

Solving the Challenge of Workholding

Workholding is another major challenge in machining metal additive parts. Printed metal parts can often have unique geometry that makes clamping difficult, and applying too much force may damage or warp the part. 

Instead, we use Blue Photon, an adhesive workholding system. It required us to change how we design fixtures and hold parts during machining, but it’s ultimately allowed us to secure these parts with greater control.

Alignment is also critical. Additive parts may have variation from the printing process, so the machining setup must account for the printed component’s actual geometry. In many cases, even relatively simple work requires 5-axis machining services instead of conventional 3-axis machining because of the part’s setup requirements or instability.

Understanding Achievable Tolerances on Features

Precision machining can achieve tolerances that 3D printing alone typically cannot, but the reference points for those tolerances matter.

When a tight tolerance is called from one machined surface to another machined surface, we can control that effectively. But when a tolerance is called from a printed surface to a machined surface, it becomes much more difficult (if not impossible) to hold because the printed surface may not be as consistent. Clear communication about these features can help ensure success on these projects.

Do You Need Machining for 3D Printed Parts?

Metal 3D printing opens the door to new design possibilities. And our precision machining can help make those possibilities fully functional.

Many of the 3D printed metal parts we machine are aluminum, but we also have experience with materials such as Inconel and 17-4 stainless steel. Whether the part is for aerospace, medical, or another demanding application, we are ready to help customers bring additive components to their final specifications.

Request a quote today from our California machine shop to discuss CNC machining for 3D printed metal parts!