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. 

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.

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.

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.

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.

1. Material cost

Materials are one of the main factors that affect CNC machining costs. The prices of different materials vary greatly. Commonly used materials include aluminum, steel, stainless steel, brass, and plastic. However, among these materials, precious metals and special alloys are more expensive. For example, the price of aluminum is relatively low, while titanium alloy is much more expensive.

2. Processing complexity

The complexity of a part's design directly affects the cost of machining. Complex geometries, fine details, and high precision all require more programming time and more complex machining processes. For example, the machining cost of a simple cylindrical part is much lower than a part with complex surfaces and internal structures. In addition, complex parts often require multiple clamping and positioning, which increases machining time and labor costs. So a lot of times when you make small changes to your design, it doesn't reduce the cost. As long as there are changes, there will be costs.

3. Quantity

The number of parts processed is also a key factor in determining costs. Generally speaking, the cost per part of a large-scale production is lower than that of a small-scale production. The reason is that the fixed costs of programming, setting up and debugging required for production can be amortized on each product. If thousands or tens of thousands of parts are processed at a time, the unit cost will be significantly reduced. On the contrary, small-scale production of a single part will be more expensive. Usually, we all know that there will be additional charges for custom colors. But the cost of 50 pieces in 5 colors will be much more expensive than 50 pieces in one color. In this case, if the total quantity of 5 colors is increased. For example, for 500 pieces of 5 colors, you will find that the price will be much lower, and there will not even be any additional charges.

4. Machine tools and tools

Different CNC machines and cutting tools affect the cost of machining. High-end five-axis CNC machines can process complex parts, but the cost will be higher than three-axis machines. In addition, if the design is more complex, it will require customized specific cutting tools or special processing, which will also increase the cost. Cutting tool wear and replacement frequency are also factors, as they will affect machining efficiency and quality.

5. Labor costs

CNC machining requires experienced technicians for programming, operation and quality inspection. Complex parts require longer programming and debugging, which further increases labor costs.

6. Other costs

Other costs include final processing (such as surface treatment, heat treatment), packaging, logistics and transportation. Some parts need to be heat treated or surface coated after processing to improve performance and durability, and these steps will increase the overall cost. In addition, the customization of packaging, logistics and transportation costs also need to be considered, especially for large or heavy parts. You may wonder about the cost of packaging, but it is an unavoidable cost. After your product is surface treated, in order to prevent your products from rubbing against each other during transportation, we will pack the products one by one. In another case, when your product is more precise, in order to prevent damage during transportation, it will be packed in wooden boxes or pallets.

In summary, there are many factors that affect the cost of CNC machining, but as a rule of thumb, the average hourly cost is roughly between $50 and $200, depending on the factors listed above.But all of this will be dispensable costs when the order quantity is relatively large.

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.

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.

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.

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.

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.

Tough as they are, these materials can be machined with the right strategy. Here’s what works:

Choose the Right Tools

Opt 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 Equipment

Machines with heavy-duty frames, high torque, and stable spindles minimize vibration—critical for precision with hard materials.

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.

The selection of tools for cutting titanium and titanium alloys depends on the specific processing method (such as milling, turning, drilling, etc.), and takes into account the characteristics of titanium: high chemical activity, low thermal conductivity, and easy work hardening. The focus is on reducing tool wear and controlling cutting temperatures. The following are the best tools for different processing scenarios:

Milling is the primary method for machining complex contours on titanium alloys. Ultrafine-grain carbide tools are the preferred choice, offering an optimal balance of hardness, wear resistance, and impact resistance.

Base material: Choose a WC-Co alloy with an 8%-12% cobalt content. (Too high a cobalt content can easily cause adhesive wear due to titanium's chemical affinity, while too low a cobalt content can result in insufficient impact resistance.)

Coating Optimization: AlCrN (aluminum chromium nitride) coating is preferred, as it has an oxidation resistance temperature of over 1100°C and reduces chemical reactions at high temperatures. TiAlN (titanium aluminum nitride) coating is an option for medium cutting speeds, offering superior wear resistance in the 600-800°C range.

Cutting Edge Design: A sharp, positive rake angle (5°-10°) and a small cutting edge radius (≤0.02mm) are recommended to minimize compression on the titanium material and reduce work hardening. For rough milling, a corrugated edge or chip splitter can be used to improve chip evacuation efficiency. Special scenarios: Metal ceramic tools (such as TiC-Ni-Mo series) can be used for high-precision finishing (such as medical implants), but they have poor impact resistance and are only suitable for small cutting volume processing.

Turning requires a balance between continuous cutting stability and anti-sticking properties:

Conventional turning: TiAlN or AlCrN-coated carbide inserts (such as ISO P or M types) are preferred. At cutting speeds of 50-100 m/min, their wear resistance and tool life are far superior to uncoated tools.

High-precision/high-surface-quality machining: Cubic boron nitride (CBN) tools are suitable for fine turning with small stock additions. They have a hardness exceeding HV3000 and are highly resistant to high temperatures (1400°C), preventing sticking wear on titanium. However, they are brittle and require low feed rates (0.05-0.1 mm/min).

The key to drilling is to address the issues of difficult chip removal and drill bit burnout:

General drilling (diameter <10mm): Cobalt-containing high-speed steel drills (HSS-Co, with a cobalt content of 5%-8%) offer better value for money, possess higher red hardness than ordinary HSS, and feature internal coolant holes (high-pressure cutting fluid delivered through the center hole) for effective heat dissipation and chip removal.

For deep holes or large-diameter drilling (diameter >10mm): Solid carbide drills (such as WC-Co alloy with a TiAlN coating) offer superior rigidity and wear resistance, suitable for high feed rates of 0.1-0.2 mm/min.

Band Saw Blades: Choose high-speed steel band saw blades (HSS-M42). These blades have a high cobalt content, excellent red hardness, and can withstand high cutting temperatures. Fine-tooth design reduces impact on the material and facilitates chip removal.

Circular Saw Blades: Carbide circular saw blades (such as WC-Co alloy with a TiN coating) are suitable for sawing larger titanium materials. The coating improves wear resistance and adhesion resistance, ensuring stable cutting.

When high-precision surface machining is required, CBN grinding wheels are the best choice: they offer high hardness, excellent wear resistance, and the ability to maintain cutting performance even at high temperatures. They also have a low chemical affinity with titanium, preventing adhesion and ensuring high-quality ground surfaces. For rough grinding, a coarser grit size improves efficiency, while for fine grinding, a finer grit size ensures precision.

In summary, titanium cutting tools must be selected specifically for the machining method, while cutting parameters (such as low cutting speeds and adequate cooling) must be coordinated to achieve efficient, high-quality machining.