How 5-Axis Machining Has Changed Aerospace Manufacturing

In the world of precision manufacturing, aerospace technology presents unique challenges. In fact, the geometries and tolerances required for parts in aerospace manufacturing surpass what is needed in most other industries. For this reason, aerospace has long been a driver of innovation, including the tools and technologies used to manufacture precision components. In this article, we’ll explore one type of precision manufacturing technology: 5-axis machining and how it has changed aerospace machining capabilities.

What Is 5-Axis Machining?

A recent evolution in CNC manufacturing, 5-axis machining makes parts production more flexible, efficient, and cost-effective. The term “axes” in CNC machining refers to the distinct motions of a tool, such as a mill or lathe, relative to a workpiece in the subtractive manufacturing process. Traditionally, CNC machines had a fixed workpiece with a tool that operated on two or three axes. With the advent of 4-axis machines, the workpiece itself could rotate on a single axis, allowing for more efficient production, as the workpiece wouldn’t need to be reset as often. With 5-axis machining, the workpiece can rotate on multiple axes, creating much greater flexibility.

The Benefits of 5-Axis Machining for Aerospace

As noted above, there are unique challenges in manufacturing parts for aerospace because components often have complex geometries and require a combination of strength and light weight. The use of 5-axis machining provides exceptional benefits for such applications, including:

Increased Efficiency

With traditional 3- or 4-axis machines, achieving complex geometries requires the workpiece to be manually reoriented numerous times in the production process. Because 5-axis machines allow the workpiece to rotate on multiple axes, the production process can easily be designed to minimize the number of workpiece resets that are needed.

More Flexible Prototyping & Complex Geometries

Flexibility is one of the primary reasons why 5-axis machining has been quickly adopted in the production of aerospace components. With five distinct axes, this CNC technology allows for parts to be designed and manufactured to meet extremely precise specifications.

The 5-axis machine’s rotational flexibility allows for machining angles that simply aren’t possible with 3-axis machines—even with multiple setups. Reducing or eliminating resets also improves accuracy, as the workpiece remains in the same “home” location throughout the production process. Additionally, because the fourth and fifth axes allow the workpiece to be moved closer to the cutting tool, the tool can be shorter, which reduces vibration and helps increase precision and improve surface finish.

Decreased Costs

Manufacturing efficiency drives down costs, but that’s not the only way that 5-axis machining saves money. For example, the capacity to rotate the workpiece helps extend the life of tools, thereby reducing overhead costs.

Looking at the bigger picture, 5-axis machining has helped revolutionize aerospace engineering by allowing for part designs that were previously cost prohibitive or simply not possible.

Demmer Manufacturing Affiliate’s Machining Capabilities

At Demmer Manufacturing, we understand that as precision machining technology advances, so do our customers’ expectations. Our affiliates utilize best-in-class precision machining technology for each application, which ensures consistent performance, competitive value, and continuity of supply. For example, our portfolio company Intrex Aerospace has adopted 5-axis machining, helping us meet the varied needs of our customers in industries ranging from defense to aerospace.

To learn more about the capabilities of our precision machining companies, explore our portfolio and visit our affiliates’ websites.