For example, if you currently machined a core or cavity insert on your traditional CNC machine in 50 hours at $65 an hour ($3,250) and added approximately $300 for consumable tooling costs,

two days of polishing (16 hrs X $50/hr) at $800 and one day of spotting at $400 (8 hrs x $50/hr) your total cost for production would total $4750. Investing in newer technology would reduce your production costs by 25 percent by decreasing machine hours to (30 x 100 = $3000), consumable tooling costs to $200 and spending fewer hours polishing (5 hrs x $50 = $250) and spotting (2 hr x $50/hr = $100).With the new technology the total cost would be reduced to $3450.

The consumable tooling lasts longer when used in the higher quality machines. The simple fact that you spend less time changing tools is a savings not to mention the ability to cut an entire part with one tool for 20 or 30 hours with no blends from tool wear.

If EDM is required, it may be possible to machine these details using newer equipment for even further savings. When companies try to cut ribs and small features with older technology, it is not cost efficient due to the existing machine quality. The new high-speed machines are capable of cutting very
small details that were previously produced using EDM.

With current technology, the finish and accuracy that will allow that mold to be closed, and spotted together (sealed off to make the part) will happen much quicker. Years ago, a mold was put into a spotting press and one to two days were spent hand-grinding and fitting the mold together. Now when these parts are cut to the necessary accuracies, it’s down to hours instead of days. That is significant. Knocking two days off your delivery time saves you time and money.

Running a machine unattended, overnight may not provide a cost savings if the older technology is only running one tool to complete the job. Some shops claim that they are doing lights-out with their older machines; however, it is just because their programs took so long to run. They leave the machines running, but at a reduced feedrate to be safe, etc. The shops believe they are getting something for free—even though it is a very low productivity level compared to the true, unattended, lights-out facilities that are talked about today.