One of the main advantages of this process is material availability as virtually any material can be CNC machined. For this reason, and its use in industry since the 1940s, CNC machining remains the most common means of prototyping to date

CNC operation is determined by computer aided design (CAD) or computer aided manufacturing (CAM) data translated into Gcode – as used by 3D printers. The precision tool path in a CNC system creates an excellent surface finish, and parts can be sanded and finished on the same machine.

The standard CRYSTAL II machining functionality built into the Hyper-i control is effective for machining shapes that are hard to polish while enhancing surface finish for improved mould release. “It requires no special insulated jigs and is performed with uncoated wire,” Combes added.

Approximations of the general parameters of each process are detailed on WayKen.com in the company’s Technology Selection Guide, and a supporting Materials Selection Guide.

"When the time came to install new, modern wire EDM technology,” he said, “we looked at a number of options. We decided again in favour of the Makino offering not only because of the control and its synergy with our die-sink CNC system, but also due to the U32j's impressive working volume (370 x 270 x 220 mm) for the footprint (2,580 × 3,165 mm). We get a very compact machine while gaining an extra 20 mm of travel in X, Y and Z."

The rapid production time of 3D printing means it is finding increased uses throughout the medical industry. WayKen SLA & SLS 3D printing for medicine can be used to make hand held appliances, concept models, and new devices in low volume, e.g. diagnostic equipment, surgical instruments, electronic apparatus and ultrasonic systems. These devices are valuable for surgical planning, simulation and also to map dental correction procedures.

Combes concluded: "Makino is an excellent product but equally important to us is after-sales service. We have always received good back-up from NCMT ever since they delivered, installed and commissioned an Okuma 3-axis vertical machining centre in 2016.

The control employs HyperCut technology, a process developed by Makino to produce surface finishes as fine as three microns Rz in standard tool steels in a three- or four-pass process. The machine was a high-accuracy package with 0.05-micron scale feedback capable of producing extremely smooth surfaces down to 0.7-micron Ra if a 7-pass process is adopted.

WayKen specializes in an ability to machine a range of plastics (opaque and optically clear) and aluminum. In the CNC process, a toolhead gradually subtracts material from a solid block. As such, molecular stability of the base material remains constant producing a part with unparalleled tensile strength.

As far as resolution is concerned, the accuracy of CNC machining at WayKen is typically higher than 3D printing, between 0.02mm and 0.05mm – 0.10mm depending on geometry. Turnaround time for 3D printing is typically faster at just 2-5 days versus 3 – 8 days for CNC. This does however come at a tradeoff with the volume of products than can be produced. A typical SLA/SLS run can create 1 – 10 parts, whereas CNC has a range of 1 – 50.

"NCMT's engineers provided a week's instruction at the outset and are always available online or at the end of a telephone for troubleshooting or if technical advice is needed."

"Extensive product knowledge and being able to impart it to our operators during training is even more crucial with EDM technology. Unless parameters are kept within close limits, machining efficiency can fall off quite quickly. It is important our staff know how to keep an eye on this.

Hampshire-based mould maker BM Injection produces moulds to make plastic products for use in high-end engineering applications in the aerospace, automotive, transportation, and sports sectors, amongst others. Every mould has to visit a die-sink and a wire-cut electric discharge machine (EDM), as well as a machining centre for hard milling. The proportion of time spent on each machine varies. In the production of BM Injection's mould tools, unless any are hard-milled on an Okuma 3-axis machining centre on-site, all three production platforms used for manufacturing the moulds were built by Makino in Japan and supplied through sole UK agent NCMT.

Combes was also impressed with the user-friendly, fixed-table, rise-and-fall tank design for its easy access on three sides for efficient loading/unloading and for easy cleaning and maintenance.

Access to the working area of the Makino U32j for component load / unload and maintenance is unrestricted due to a programmable, three-sided drop-tank system.

in May 2022, a U32j wire EDM machine was fitted with the same Hyper-i control system as a Makino EDAF3 H.E.A.T. EDM die-sinker that arrived in 2019, at the same time as a Makino D200Z 5-axis machining centre from the same Japanese source.

“Traditional” processes at WayKen cover CNC plastic/metal parts machining, vacuum injection molding and rapid injection molding. In the case of CNC machining, a solid block of raw material can be used.

The primary SLA material used by WayKen is an ABS-like photopolymer, suitable for use in the lost-wax method of casting favoured in jewelry making and dental industries. SLS uses powdered Nylon feedstock, which acts like a support material throughout 3D printing, cutting down post-processing times. Parts made using SLS also benefit from the potential of nesting meaning that more designs can be 3D printed within the same build.

In some cases, it may even be beneficial to combine both additive and subtractive manufacturing process to complete an end goal. As an example, SLA and SLS could be used as a preliminary stage before moving the CNC machining.

Reliable unattended running is achieved via the effective, automatic, jet-less wire rethreading system that uses the X, Y, U and V axes to find an optimum cutting restart position with the wire clear of the workpiece surface.

In automotive, WayKen applies a plethora of CNC prototyping and rapid tooling methods to the production of spare parts. The services are useful to car manufacturers running limited trials of a car/motorcycle, and allow volume customization. WayKen automotive rapid prototyping is delivered as a complete service, guiding customers through proof of concept design reviews and mechanical component engineering tests, to show car projects and exterior/interior prototypes.

Luckily, the company’s quoting system quickly responds to enquiries within 24 hours by our allowing “On-time delivery — every time, no exceptions.” Request a quote from WayKen Rapid online now at WayKen.com.

The question is – which technology should you choose? As a WayKen spokesperson states, “it is very difficult to get a standard answer to the cost comparison between 3D printing and CNC machining.” Instead, technology should be selected based on application.

CNC machined parts at WayKen on the other hand can be used to make functional prototypes which are suitable for engineering evaluation and testing. In contrast to the SLA and SLS services offered, CNC machining requires specially trained engineers to pre-program the processing parameters and toolpaths, then machine according to the programs. Manufacturing costs are therefore quoted taking the extra labor into account. CNC’s advantage is for machining parts with special requirements such as dimensional tolerances and surface qualities.

Established in Hong Kong and located in Shenzhen, WayKen is a contender for China’s most experienced prototype manufacturer. The WayKen Prototype shop operates across two sites, one for plastic and one for metal. In total, the facilities span 20,000 square feet, employing over 60 dedicated personnel. WayKen’s specialist prototyping services include 3D printing (particularly SLA and SLS), CNC milling and rapid tooling technology.As a service bureau operating within high value automotive, medical, and aerospace industries, WayKen Rapid’s expertise is in selecting the right technology for the specific application, and delivering results at a cost competitive with the west.

3D printing services at WayKen are primarily laser-powered, offering a high level of speed and accuracy. WayKen stereolithography (SLA) is a UV based curing process, and selective laser sintering (SLS) uses a carbon dioxide laser.

SLS and SLA 3D printing are useful for fast response solutions. With digital operational tools like slicer software, the process does not require as much specialized training as CNC machining. With little labour involved, the manufacturing cost of 3D printing is priced based on the amount of materials. As larger parts cost more 3D printing is advantageous for small volumes and lightweight parts. Realtively simple structures, wth less demand for surface quality and precision parts, also benefit the most from WayKen’s 3D printing services. The technology is ideal for protoyping small medical devices, industrial tooling, and outer covering of electrical tools.

Combes was particularly pleased with the bidirectional HyperConnect Industry 4.0 network connectivity for remote machine monitoring and interlinking of all manufacturing information. This standard software enables access via the cloud to BM Injection's Open Mind OPTICAM wire EDM computer-aided manufacturing software. The CAD/CAM information occupies the top monitor of the twin-screen control and can be viewed and operated as if it were on-board, while Makino's process control screen occupies the lower monitor.

The U32j is capable of utilising wire down to 0.07 mm diameter, which is smaller than most machines are able to accommodate. There will be a need for smaller gauges and the accompanying diamond guides for the future production of BM Injection's optical industry moulds. Combes pointed out a reduction in wire consumption coupled with an increase in cutting speed on every job completed so far on the U32j compared with the nearly 20-year-old wire-cut EDM machine that was replaced.

The competitive price point for all services, according to the company’s website, is “normally 30%-50% less than the US/European prices, due to lower labor costs. Moreover allowing a quick project start compares to other rapid prototype companies.”

BM Injection Director Mark Combes said: "With a wire machine it’s all about producing sharp radii and smooth surfaces, especially on the interior of ejector pin holes. That is exactly what the U32j has produced right from the start due to a combination of rigid machine build, thermal stability and the Hyper-i control."

The Hyper-i Windows-based, twin-touch-screen CNC system, with an intuitive interface similar to that found on tablets and smartphones, includes advanced functions to support operators of all skill levels at every step of the machining process. The control contains an extensive library of cutting conditions that automatically optimises the erosion process, even for sealed and poor flush applications. It also enables easy access to and selection of power settings to produce accurate results in the fastest possible cycle times.

The Makino U32j wire-cut EDM machine on the shop floor at BM Injection. On the right is the twin-screen control with HyperConnect remote connectivity to the mouldmaker's Open Mind CAM system (top). Below is Makino's process control screen.

BM Injection also uses the Protech galvanic protection offering from Makino, which prevents rusting and oxidation of steel, carbide and aluminium. By placing an electrode plate in the bottom of the tank and giving it a positive charge, the workpiece is held at a negative potential that constantly attracts positive ions.