Nickname | quit

News Center

Industry dynamics

Your current location： Home page

Your current location： Home page

How One-Setup 5-Axis Machining Center Improves Accuracy in Small Irregular Surface Parts

How One-Setup 5-Axis Machining Center Improves Accuracy in Small Irregular Surface Parts

Manufacturing small parts with irregular surfaces, deep cavities, or hollow structures presents a unique set of challenges.

While prototype results may appear acceptable, maintaining consistent accuracy and surface quality during repeated production often proves difficult.

In many cases, the root cause is not tooling or programming—but the necessity of multiple setups during machining.

The Manufacturing Challenge Behind Small Irregular Surface Parts

Small components with complex geometries often combine several demanding characteristics:

Freeform or irregular surfaces

Tight dimensional tolerances

Thin walls or internal cavities

High requirements for surface finish and visual consistency

For such parts, even minor deviations caused by repositioning can significantly affect final quality. These issues become more pronounced when the part must transition from prototype to small-batch or repeat production.

Why Multi-Setup Machining Often Fails in Complex Surface Applications

Traditional 3-axis or indexed 3+2 machining typically requires multiple setups to access different surfaces.Each setup introduces a new reference point, increasing the likelihood of cumulative error.

Common consequences include:

Inconsistent surface transitions between machining stages

Local overcutting or residual material in deep cavities

Variations between prototype and production parts

Hidden internal defects that are difficult to detect visually

For complex surface machining, these risks grow as part size decreases and geometric density increases.

Application-Driven Design of a Custom Small 5-Axis CNC Machining Center

To address these challenges, SZGH developed a custom small 5-axis CNC machining center specifically for application scenarios involving small, irregular, and high-detail components.

Rather than focusing on maximum speed or oversized travel ranges, the design prioritizes:

One-setup machining for full-part access

Stable reference alignment throughout the process

Controlled tool orientation for complex surfaces and cavities

This approach aims to improve machining predictability rather than relying on post-process correction.

What Changes When Machining Is Completed in One Setup

Completing machining operations in a single setup fundamentally changes the manufacturing outcome:

Consistent Accuracy

A unified reference system eliminates repositioning errors and improves dimensional stability.

Improved Deep Cavity and Irregular Surface Control

Continuous 5-axis motion allows the tool to maintain optimal contact angles, reducing internal defects.

Reduced Material Waste

Stable tool paths minimize conservative allowances and rework.

Better Surface Finish

Smoother surface transitions reduce the need for secondary polishing or manual finishing.

Consistency from Prototype to Production

The same machining logic can be reliably repeated, ensuring part-to-part uniformity.

Case Study: Butterfly Pendant Machining with Complex Surfaces

To validate performance in real-world conditions, SZGH applied this machining approach to a butterfly-shaped pendant, a small component characterized by dense curves, thin sections, and high symmetry requirements.

Typical challenges before optimization included:

Discontinuous surface transitions caused by multiple setups

Variations in wall thickness near internal cavities

Inconsistent surface quality requiring manual rework

Results after one-setup 5-axis machining:

Continuous and uniform surface geometry

Improved internal structure integrity with no visible defects

Significantly reduced polishing effort

Stable replication of machining results across multiple parts

What This Means for Manufacturers Facing Similar Parts

If your components involve:

Small dimensions with complex or freeform surfaces

Deep cavities or hollow internal structures

High expectations for surface quality and consistency

A need to scale from prototype to repeat production

Then the machining strategy—not just machine specifications—deserves careful reconsideration.

SZGH’s custom small 5-axis CNC machining center was developed specifically for these application-driven requirements.

For further discussion on part suitability or machining examples, feel free to reach out.

5 axis cnc machining center,small 5 axis cnc,one setup machining,Small Irregular Surface Parts,Complex Surface Applications,Small 5-Axis CNC Machining Center

Scan two-dimensional code with mobile phone

SZGH Chinese New Year Service Notice

SZGH CNC and Automation Solutions to be Showcased at Indonesia Exhibition – We cordially Invite You to Visit!