Eliminate Sharp Internal Corners to Cut Machining Costs

Sharp internal corners in machined parts require specialized tooling like end mills with small diameters, which are slower and more expensive. To cut a sharp corner, the tool must make multiple passes or use a smaller tool, increasing cycle time and tool wear. This adds significant cost per part.

Instead, design internal corners with a radius that matches a standard tool size. A radius of at least 1/8 inch allows the use of a larger, more rigid end mill, reducing machining time and improving surface finish. This simple change can cut machining costs by 20-30% for complex parts.

Applying this principle across all internal features reduces the need for multiple tool changes and secondary operations. The result: faster production, lower tooling costs, and better part consistency. Always consult your manufacturer's preferred tool sizes to maximize savings.

#CostEstimation# #Tolerancing# #StressAnalysis#