CNC Machining Medical Components: Things You May Want to Know

In the world of manufacturing, precision and complexity are the name of the game. As industries evolve, the demand for components with intricate geometries and high precision is on the rise. When it comes to meeting these demands, not all CNC machines are created equal. 5-axis CNC machines stand out as the gold standard for manufacturing complex and precision parts.



Why should you choose a factory equipped with 5-axis CNC technology for your project? How to Evaluate if 5-Axis Machining is Right for Your Production Needs?

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1. Assess Your Part Complexity and Geometry


Complex Geometries:• If your parts have intricate shapes, contours, or multiple faces that need to be machined, 5-axis machining is highly beneficial. It allows for simultaneous movement along multiple axes, enabling the creation of complex geometries that are difficult or impossible to achieve with 3-axis machines.• Example: Aerospace components, turbine blades, and medical implants often require complex shapes that are best suited for 5-axis machining.Multi-Sided Parts:• If your parts need to be machined on multiple sides without manual repositioning, 5-axis machines can significantly reduce setup times and improve accuracy. This is particularly useful for parts that require machining on five or six sides.Tight Tolerances and High Precision:• 5-axis machines are capable of achieving tighter tolerances and higher precision due to their ability to maintain optimal tool orientation and minimize tool vibration. If your parts require high precision, 5-axis machining can deliver the required accuracy.



2. Evaluate Your Production Volume and Efficiency Needs



High-Volume Production:• For high-volume production runs, 5-axis machining can offer significant efficiency gains. The ability to perform multiple operations in a single setup reduces cycle times and increases throughput.• Data Point: According to a study by the Association for Manufacturing Technology (AMT), 5-axis machining can increase production efficiency by up to 40% compared to 3-axis machining.Low-Volume, High-Mix Production:• If your production involves a high mix of parts with varying complexities, 5-axis machines can provide the flexibility needed to switch between different jobs quickly. This can lead to faster setup times and reduced downtime.Just-in-Time (JIT) Manufacturing:• For businesses that operate on a JIT basis, the faster turnaround times and increased efficiency of 5-axis machining can help meet tight delivery schedules and reduce lead times.



3. Consider Material and Part Size Requirements



Material Versatility:• 5-axis machines can handle a wide range of materials, including metals (aluminum, stainless steel, titanium), plastics, and composites. If your production involves diverse materials, 5-axis machining offers the versatility needed to process them effectively.Large Part Sizes:• Some 5-axis machines are designed to accommodate larger workpieces, which can be advantageous if your production includes large or oversized parts. However, it’s important to ensure that the machine’s working envelope meets your size requirements.





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Conclusion：


When it comes to manufacturing complex and precision parts, the advantages of 5-axis CNC machining are clear. From unmatched precision and efficiency to the ability to handle the most complex geometries, 5-axis CNC machines offer a level of capability that is unmatched by traditional machining methods. By choosing a factory equipped with 5-axis technology, you are ensuring that your project is in the hands of experts who can deliver superior quality, consistency, and efficiency.So, if you're looking to take your manufacturing to the next level, consider partnering with a factory that has 5-axis CNC machines. The benefits are undeniable, and the results will speak for themselves.

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Before we discuss what materials cannot be CNC machined, we first need to understand the principles and limitations of CNC machining, and then see what materials are not suitable for CNC machining. CNC machining has become one of the core technologies of modern manufacturing due to its high precision, high efficiency and wide applicability. However, not all materials are suitable for machining by conventional CNC processes. The physical or chemical properties of some materials can cause excessive tool wear, poor machining quality, and even damage to machine tools. This article will explore which materials are difficult or impossible to use CNC machining, and analyze the reasons behind it and possible alternatives.CNC machining is usually achieved by cutting materials with tools, which mainly depends on two factors. One is the hardness of the tool. The tool must be harder than the material being machined, otherwise it will wear out quickly. The second is material stability: the material must have a certain strength to avoid deformation or fragmentation due to cutting force. If the material cannot meet the above conditions, conventional CNC machining will be difficult to carry out.1. Superhard materials:Typical materials: natural diamond, cubic boron nitride (CBN)Processing difficulties: The hardness of diamond is as high as Mohs 10, and CBN is close to 9, which is much higher than conventional carbide tools (hardness is about 8-9). The tool will quickly become blunt or even break during cutting.Alternative solutions:Use electrical discharge machining (EDM) or laser cutting to remove materials using heat or discharge principles.2. Highly brittle materialsTypical materials: ordinary glass, unsintered ceramics, high-purity graphiteProcessing difficulties:The material is prone to breakage during cutting, and burrs or cracks are generated on the edges, making it difficult to ensure accuracy. For example, glass may shatter instantly under tool pressure.Alternative solutions:Use grinding technology (such as precision grinders) or water jet cutting to reduce direct impact.3. Highly viscous or soft materialsTypical materials: rubber, silicone, soft plastics (such as PE, PU)Processing difficulties:The material is highly elastic, and the tool is prone to "pulling" rather than cutting, resulting in deformation or rough surface. Soft plastics may also melt due to frictional heat and stick to the tool.Alternatives:Freeze curing: Processing after hardening the material at low temperature (such as cooling rubber with liquid nitrogen).Use high-speed spindles (above 20,000 RPM) to reduce heat accumulation.4. High-temperature sensitive materialsTypical materials: lead, tin, PVC plasticsDifficulties in processing:Low-melting-point metals (such as tin melting point 232°C) are easy to soften and stick to the tool during high-speed cutting; PVC releases toxic chlorine gas at high temperatures, which endangers operators.Alternatives:Control cutting temperature (such as using coolant), or use 3D printing or injection molding instead.5. Heterogeneous composite materialsTypical materials: Carbon fiber reinforced composite materials (CFRP), glass fiberDifficulties in processing:Material anisotropy leads to uneven cutting force and extremely fast tool wear; carbon fiber may also delaminate, affecting structural strength.Alternatives:Use diamond-coated tools and optimize cutting parameters (low feed, high speed).It is worth noting that although many materials are difficult to process with conventional CNC, they are not absolutely "unprocessable". The following methods can be used to break through the limitations:Special tools: such as polycrystalline diamond (PCD) tools for processing carbon fiber.Process improvement: combined with cooling technology (such as cryogenic processing), vibration suppression, etc.Hybrid process: CNC rough processing first, then EDM or laser finishing.For example, although nickel-based high-temperature alloys (such as Inconel) have extremely short tool life due to high strength and high thermal conductivity, they can still be processed with special ceramic tools and extremely low feed speeds, but the cost is extremely high. ConclusionAlthough CNC processing is powerful, its limitations also remind us that material properties and processing technology need to be highly matched. When facing special materials, engineers need to comprehensively consider cost, efficiency and quality, and flexibly choose traditional cutting, special processing or additive manufacturing solutions. In the future, with the development of technologies such as superhard tools and intelligent cooling systems, the boundaries of CNC may be further broadened, but "applying technology according to materials" will always be the core logic of the manufacturing industry.

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In the world of CNC machining, the choice of metal materials directly affects machining efficiency, part accuracy and final cost. Although no metal can "take all" in all machining scenarios, some metals have become the "darlings" of CNC machining due to their excellent comprehensive performance. They are not only adaptable to a variety of machining processes, but also can show stable performance in the fields of auto parts, aerospace, etc.

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Aluminum alloy: the all-rounder in CNC machining

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▶ Aluminum alloy is one of the ideal materials for CNC machining, especially in the fields of auto parts and aerospace.In terms of processing performance, aluminum alloy has moderate hardness (the hardness of common 6061 aluminum alloy is about 95HB), low cutting resistance, slow tool wear, and can greatly improve processing efficiency. Its thermal conductivity is excellent, about 3 times that of steel, and the heat generated during processing can be quickly dissipated to avoid the accuracy of parts affected by thermal deformation. In addition, aluminum alloy has good plasticity, and smooth surface quality can be obtained whether it is milling, turning or drilling, without complicated subsequent processing.In terms of cost, the price of aluminum alloy raw materials is relatively affordable, and the material utilization rate is high during processing, which is suitable for mass production. For example, engine brackets in the auto parts field and lightweight structural parts in aerospace are mostly processed with aluminum alloys, which can meet strength requirements and achieve weight reduction goals.

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Brass: The “stable” material for precision machining

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▶ Brass has become a popular choice for precision parts processing due to its excellent cutting performance.Brass has a low hardness (about 50-100HB) and a uniform internal structure. It is not easy to produce burrs and cracks during processing, and can easily achieve high-precision dimensional control (tolerance can be stabilized within ±0.01mm). It has good self-lubrication, is not easy to stick to the tool during cutting, and can reduce tool loss. It is especially suitable for processing parts with fine threads and complex holes, such as hydraulic valve components in auto parts and connectors in precision instruments.In addition, brass has good conductivity and corrosion resistance. After processing, it can meet the needs of some scenarios without additional plating, further reducing production costs. However, brass has a high density and is relatively limited in its application in weight-sensitive aerospace parts.Compared to brass, copper is widely used in new energy vehicle charging systems, with CNC-machined copper and copper alloy components being widely used. High-precision copper parts (such as charging gun terminals and battery connection pins) ensure stable current transmission. In the battery system, CNC-machined copper tabs and busbars efficiently collect power, while copper sleeves precisely adapt to the heat dissipation structure, balancing electrical and thermal conductivity. In the cooling system, precision-machined copper tubes, with their excellent dimensional accuracy, ensure reliable heat dissipation under high-voltage environments. Connectors and sensor contacts made from brass and other alloys, manufactured through CNC machining, maintain excellent conductivity while meeting complex assembly requirements through high-precision morphology, fully supporting the efficient operation of the vehicle's power transmission and thermal management systems.

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Mild steel: a cost-effective choice

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▶ Low carbon steel (carbon content <0.25%) is a "frequent visitor" in the industrial field and also occupies an important position in CNC processing.Its strength and toughness are balanced, and the cutting force during processing is moderate, which is suitable for various conventional processing technologies. Low carbon steel is cheap and the raw material supply is sufficient, which is suitable for mass production of structural parts, such as chassis brackets in auto parts and gear blanks in mechanical transmission. After heat treatment, low carbon steel can also improve the surface hardness and meet the wear resistance requirements.However, it should be noted that low carbon steel is easy to rust, and usually needs to be electroplated or painted after processing; and its thermal conductivity is not as good as aluminum alloy, so it needs to be cooled during high-speed processing to avoid deformation of parts.

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Stainless steel (304/316): the “preferred material” in the field of corrosion resistance

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▶ In scenarios with high requirements for corrosion resistance, 304 and 316 stainless steel are the first choice for CNC machining.304 stainless steel contains chromium-nickel alloy, has strong oxidation resistance and stable processing performance, and is suitable for making parts for food machinery and medical equipment; 316 stainless steel has better resistance to salt spray and high temperature corrosion due to the addition of molybdenum, and is often used in aerospace pipeline systems and exhaust parts in auto parts.Although stainless steel has a high hardness (about 150-200HB) and the tool wears faster during cutting, high-precision parts can still be efficiently processed by selecting carbide tools and optimizing cutting parameters (such as reducing feed speed and strengthening cooling).

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Key principles for choosing the right metal



▶ To determine whether a metal is suitable for CNC machining, the following factors need to be considered comprehensively:• Machining efficiency: Material hardness and cutting resistance directly affect machining speed and tool life;• Precision control: Thermal conductivity and plasticity determine whether the parts are easily deformed due to machining heat or stress;• Cost adaptation: Raw material prices, machining energy consumption, and subsequent processing costs must match the project budget;• Scenario requirements: The strength, corrosion resistance, weight and other properties of the parts must meet the special requirements of the application field (such as the requirements of aerospace for lightweight and high temperature resistance).Different metals have their own advantages, and the selection needs to be combined with the drawing requirements, performance indicators and cost budget of the specific project. If you are struggling with the selection of parts, or want to know the feasibility of machining a certain metal, please contact us. Our team of engineers is familiar with the machining characteristics of various metals and can provide customized solutions according to your needs, from material selection to process optimization, to escort your project throughout the process.

In the manufacturing world, CNC machining has become a cornerstone for producing precision parts—from auto components to aerospace components—thanks to its unmatched accuracy and efficiency. If you’re considering CNC machining for your project, one question likely tops your list: How much does it cost to machine a part with CNC?The truth is, there’s no one-size-fits-all answer. CNC machining costs depend on a mix of factors, from the materials you use to the complexity of the part. Below, we’ll break down these factors, explain how costs are calculated, and share tips to keep your expenses in check. Let’s dive in.

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Key Factors That Influence CNC Machining Costs



Material CostsThe type of material you choose is one of the biggest cost drivers. Common metals like aluminum, copper, and steel are budget-friendly, with prices often ranging from tens of yuan per kilogram. On the other hand, high-performance materials—such as titanium alloys (used in aerospace) or specialty alloys—are far pricier. For example, aviation-grade titanium can cost thousands of yuan per kilogram, due to its scarcity, difficult refining process, and tough machining properties. Material specifications also matter. Higher-quality, precision-grade materials (with tighter tolerances or better surface finishes) will cost more than standard grades, as they meet stricter industry standards.

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Part ComplexityA part’s shape and structure directly impact how much time and effort go into machining it—and thus, the cost.● Simple parts: Basic shapes like cubes, cylinders, or flat plates are easy to machine. They require fewer tool changes, simpler programming, and minimal setup, keeping costs low. A simple aluminum cylinder, for instance, might cost just 1.5 USD.The following example is a project we processed, which is a component of the gear lever for racing cars.

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● Complex parts: Parts with intricate curves, irregular shapes, tiny features (like micro-holes), or internal channels are far more challenging. They need advanced programming to map tool paths, multiple setups (to reach all angles), and sometimes specialized tools. For example, an aircraft engine blade—with its complex, aerodynamic curves—can cost hundreds of dollars or more to machine.The picture below is a project we processed, which is an aluminum automobile intake manifold.

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Precision Requirements



Tighter tolerances and smoother surface finishes mean higher costs.● Standard precision: Most everyday mechanical parts need tolerances around ±0.1mm. These are straightforward to achieve with basic CNC equipment, so costs stay reasonable.● High precision: Parts for medical devices or aerospace often require tolerances as tight as ±0.01mm (or even less). To hit these targets, manufacturers must use high-end, ultra-precise machines, run multiple finishing passes, and conduct rigorous quality checks—all of which add time and expense.

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Production Volume



How many parts you need affects the cost per unit.CNC machining has “fixed costs” upfront: programming the machine, setting up tools, and debugging. For small batches (e.g., 1–10 parts), these fixed costs get spread across fewer units, making each part more expensive. For example, 1 custom part might cost 15 USD.But with larger volumes (e.g., 100+ parts), those fixed costs are divided among more units, driving down the per-piece price. That same part could drop to 8 USD each when produced in bulk.



Machinery and Technology



Not all CNC machines are created equal—and their costs reflect that.● 3-axis machines: These handle flat or simple 3D parts (like plates or blocks) and are affordable, with hourly rates often between 100–300 yuan.● 4-axis or 5-axis machines: These tackle complex, multi-angle parts (like turbine blades) but are pricier to buy and operate. Hourly rates for 5-axis machines can range from 500–1000 yuan or more.Processing techniques also matter. Milling, turning, and drilling are standard (and cheaper), while specialized methods like EDM (electrical discharge machining) or grinding cost more due to unique equipment and longer processing times.The following pictures are the 5-axis machines and EDM machines in our factory.

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How CNC Machining Costs Are Calculated



Manufacturers use three main pricing models, depending on your project’s needs:



▶ Hourly Billing This is common for projects with hard-to-estimate timelines (e.g., one-off complex parts). The formula is simple:Total cost = Processing time × Hourly rateThe hourly rate covers everything: machine depreciation, energy use, labor, and overhead. As noted earlier, rates vary by machine type—3-axis machines are cheaper than 5-axis ones.

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▶ Per-Piece Billing Ideal for mass production (e.g., 1000+ identical parts) where processing time and complexity are consistent. The per-piece price includes: ● Material costs● Machining time● Tool/equipment wear● A small profit margin For example, a simple plastic bracket might cost a few yuan per piece, while a complex metal gear could cost hundreds.
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▶ Comprehensive Billing Best for mixed projects (e.g., multiple part types) or long-term partnerships. This model combines material costs, processing time, complexity, and volume to create a custom quote. For instance, an order with 5 different parts would have each part’s costs calculated individually, then adjusted based on total volume and project difficulty.


Tips to Reduce CNC Machining Costs



Want to keep costs low without sacrificing quality? Try these strategies:



1. Optimize Your Part Design Simplify shapes to cut down on machining steps. Avoid unnecessary curves, tiny features, or overcomplicating structures—ask: Does this detail serve a critical function?Also, design for material efficiency. For example, combining two small parts into one larger piece reduces assembly time and material waste.2. Choose the Right Material Balance performance and cost. If a part doesn’t need aerospace-grade titanium, try a cheaper alternative with similar properties (e.g., aluminum alloys for non-critical components).Buy in bulk or use standard-sized materials—custom cuts or rare sizes often come with premiums.3. Order in Larger Volumes If your project allows, scale up production. As we saw earlier, bulk orders lower the per-piece cost by spreading fixed costs across more units.4. Partner with Experienced Suppliers A skilled manufacturer can optimize tool paths, reduce setup time, and avoid errors—saving you money. Look for suppliers with advanced equipment, a track record of efficiency, and transparent pricing.5. Plan for Long-Term Partnerships Building a long-term relationship with a supplier often leads to better rates, priority scheduling, and tailored cost-saving solutions (e.g., bulk material discounts).



Final Thoughts



CNC machining costs depend on materials, complexity, precision, volume, and machinery—but with the right strategies, you can keep expenses manageable. Whether you need a single prototype or 10,000 production parts, the key is to align your design and volume with your budget.If you’re ready to get a custom quote, reach out to us. Our team uses state-of-the-art CNC machines and decades of experience to deliver accurate, cost-effective parts—on time, every time. Share your part drawings and requirements, and we’ll craft a detailed, transparent estimate tailored to your project.Let’s make your next project a success—contact us today!

In the world of manufacturing, CNC machining stands as a cornerstone of precision—yet not all materials play by the same rules. While metals like aluminum or mild steel glide through the machining process, others pose unique challenges, testing the limits of tools, equipment, and expertise.What makes a material "difficult" to CNC machine? It’s a mix of physical properties: hardness that resists cutting, poor thermal conductivity that traps heat, chemical reactivity that damages tools, and even work hardening that makes each pass harder than the last.Let’s dive into the materials that top the list of "hardest to machine"—and how manufacturers tackle them.



1. Titanium Alloys (Especially High-Strength Grades Like TC4)



Titanium alloys are stars in aerospace, medical devices, and high-performance engineering—thanks to their strength-to-weight ratio and corrosion resistance. But for CNC machinists, they’re a tough nut to crack.High strength at high temps: Even when heated, titanium retains its strength, increasing cutting force and straining tools.Terrible thermal conductivity: It conducts heat 5x less than steel and 10x less than aluminum. Most cutting heat stays trapped at the tool tip, accelerating wear.Chemical reactivity: At high temperatures, titanium reacts with tool materials (like carbide), causing "built-up edge"—where material sticks to the tool, ruining surface finishes and shortening tool life.For example, machining high-strength titanium alloys like TC4 often cuts tool life to a fraction of what it would be with steel. Shops need rigid machines and specialized tools to avoid vibration and maintain precision.



2. Nickel-Based Superalloys (e.g., Inconel 718)



Superalloys are designed to thrive in extreme heat—think jet engines, gas turbines, and nuclear reactors. But their resilience makes them a nightmare for CNC machining.Extreme hardness and strength: Even at room temperature, they’re far harder than steel, requiring massive cutting force.Severe work hardening: As you cut, the material’s surface hardens dramatically (up to 50% harder than the base metal), making subsequent passes exponentially harder.Heat traps: Poor thermal conductivity concentrates heat at the tool tip, leading to overheating and premature tool failure.Take Inconel 718, a common nickel-based alloy: tool wear rates here are 3–5x higher than with mild steel. Machinists must carefully select tools (like ceramic or cubic boron nitride) and tweak parameters to avoid disaster.



3. Ultra-High-Strength Steel



Used in automotive safety parts, armor, and aerospace structures, ultra-high-strength steel (UHSS) offers unmatched toughness—but machining it demands next-level skill.Off-the-charts hardness: Many grades hit HRC 50+, requiring tools with extreme wear resistance (like CBN or ultra-fine carbide).Tough, unruly chips: Its high toughness leads to long, stringy chips that wrap around tools or parts, disrupting precision and safety.Heat and vibration: Cutting generates intense heat (hard to dissipate), while the material’s rigidity causes vibration—ruining surface finishes and accuracy.Machining UHSS often requires heavy-duty machines with vibration-dampening features to keep cuts stable.



4. Titanium-Aluminum Intermetallic Compounds



A newer class of high-temperature materials, titanium-aluminum (Ti-Al) intermetallics promise lightweight strength for aerospace—but their machining difficulty is off the charts.Brittleness at room temp: Unlike pure titanium, Ti-Al alloys are brittle, making them prone to cracking during cutting.Worse thermal conductivity than titanium: Heat builds up even faster, putting tools under extreme stress.Low fracture toughness: The material cracks easily under cutting force, damaging both parts and tools.As a newer material, machining Ti-Al intermetallics is still being refined—requiring experimental tooling and slow, precise feeds.

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How to Machine These "Impossible" Materials



Tough as they are, these materials can be machined with the right strategy. Here’s what works:Choose the Right ToolsOpt for ultra-hard, heat-resistant materials:●Cubic Boron Nitride (CBN): Handles high temps and hard materials like UHSS.●Ceramic tools: Resist heat and chemical reactions (great for superalloys).●Ultra-fine carbide: Balances toughness and wear resistance for titanium.Tweak Cutting Parameters●Slow down cutting speeds to reduce heat.●Use moderate feed rates and shallow depths to avoid overloading tools.●Add high-pressure cooling (up to 1000 psi) or oil mist lubrication to flush heat and chips.Upgrade Your Process●Step-by-step machining: For complex parts, take smaller cuts to avoid stress.●Pre-machining heat treatment: Soften materials temporarily to ease cutting.●High-speed machining (HSM): Reduces vibration for brittle materials like Ti-Al. Invest in Rigid EquipmentMachines with heavy-duty frames, high torque, and stable spindles minimize vibration—critical for precision with hard materials.



Why These Materials Matter



Despite the hassle, these "difficult" materials are irreplaceable. Titanium alloys lighten aircraft, superalloys power jet engines, and UHSS keeps cars safe. Their performance benefits far outweigh machining challenges—if you have the expertise to handle them.Need help machining tough materials? Our team specializes in CNC machining for titanium, superalloys, and beyond. With 19+ years of experience, advanced equipment, and custom tooling, we turn "impossible" parts into reality.Contact us today for a free quote—and let’s tackle your toughest projects together.