CNC milling: what is it and in which industries is it used?

CNC milling of copper and aluminum allows for forming complex parts from a single block of material. What exactly is this process, in which fields is it used, and what are its advantages?

What is CNC milling?

CNC milling is a type of machining process that mechanically removes layers of material to give the workpiece a desired shape, dimensions, and specific properties. It allows for fast and precise shaping of various surfaces, including metal ones such as copper or aluminum, combining traditional machining methods with computerized numerical control (CNC) technology. Thanks to CNC, the entire process is automated, making it ideal for projects requiring high precision or intricate shapes.

At Electris, we have 3- and 5-axis machines, enabling us to carry out the most demanding projects, such as producing components up to 4 meters long. The parts are manufactured automatically by rotating cutting tools, and during milling, we can process various surfaces—flat, shaped, grooves, channels, teeth, and more.

How does metal milling work?

CNC milling of copper and aluminum involves several stages. The first and crucial step is creating an appropriate design on the computer, which is then processed and turned into a control plan for the tools. A programmer introduces the correct algorithm, thus creating commands that are executed via the PLC controller.

The CNC metal machining takes place at the final stage and is carried out automatically (without operator intervention). The milling cutter mounted in the spindle removes the top layer of material, allowing the desired size, shape, and properties of the element to be achieved.

The Main CNC Milling Techniques

CNC milling can take various forms, influenced primarily by the structure and movement of the milling machine, as well as the arrangement of the cutting tools.

• Based on the structure of the milling machine, we differentiate between full CNC milling (three-sided), partial milling (two-sided), and free milling (one-sided).
• Based on the movement of the milling machine, we differentiate between concurrent and countercurrent CNC milling.
• Based on the arrangement of the cutting tools, we differentiate between cylindrical (peripheral), face, and angled CNC milling.

Choosing the right CNC metal machining technique is as important as properly programming the entire process and is done fully individually, depending on the customer's needs.

What materials can be CNC-milled?

One of the technological processes we use at Electris is CNC milling of aluminum and copper, which allows us to create high-quality components according to our customers' specifications. However, it is also possible to CNC mill other materials, such as stainless steel, plastics, and even wood.

In which industries is metal milling used?

Due to its high precision, efficiency, and the ability to machine copper, aluminum, and many other materials, CNC milling is used in various industries. It is most commonly used to produce parts and components for:

• Energy industry (e.g., to produce components such as bus bars, which conduct electricity and can be installed in various control cabinets, generators, converters, and many other devices used in both conventional and renewable energy);
• Automotive industry (e.g., engine blocks, crankshafts, cylinder heads, exhaust system components, and other mechanical parts);
• Machinery industry (e.g., in the production of gears, shafts, bearings, and housings);
• Electronics industry (e.g., in the production of coolers and parts for electronic devices);
• Medical industry (e.g., in the production of surgical tools, implants, and prosthetics);
• Construction industry (e.g., in the production of windows, doors, railings, or architectural elements).

Of course, this is not all. The vast possibilities offered by CNC milling are also used in the aerospace, space, defense, and jewelry industries.

What is the role of CNC machining in the production of copper components?

CNC machining is widely used in the preparation of copper or aluminum components, such as bus bars, due to its precision, repeatability, and efficiency. What exactly can be done with CNC technology?

• Material cutting – CNC allows for precise cutting of copper or aluminum bars, such as bus bars or connectors, to exact lengths.
• Hole drilling – With CNC, holes of various diameters can be drilled in precisely specified locations of components. These holes are essential for mounting elements in electrical systems and for connecting wires and other components.
• Grooving and channel milling – CNC can be used to mill grooves or channels on the surface of various bus bars, which can be used for wiring or increasing the contact surface.
• Shaping – CNC machining allows for cutting complex bus bar shapes, including bends, curves, and other non-standard geometries, necessary to fit the bus bars to specific installation conditions and customer requirements.
• Material removal – CNC enables precise material removal, which is important for achieving the desired weight and shape of bus bars, as well as optimizing their electrical efficiency.
• Edge and finishing machining – e.g., precise rounding of bus bar edges, which reduces the risk of electrical breakdowns and mechanical damage during installation and operation.

Thanks to CNC machining, bus bars can be produced with high accuracy and in accordance with design requirements, ensuring reliability and efficiency in energy distribution systems.

Why choose CNC milling services?

CNC milling services are extremely popular worldwide, mainly due to the ability to quickly produce elements with precise shapes and dimensions. Using high-quality computer-controlled machines allows for repeatable production, the manufacturing of large quantities of parts, and reducing the unit cost of production.

Moreover, CNC milling is a way to reduce human error and material waste, increase work safety, and optimize the use of human resources. It is recommended for anyone who values time, high-quality parts, and cost reduction.

CNC Milling of Aluminum and Copper at Electris

At Electris, we offer CNC milling and other CNC machining methods for aluminum and copper, including CNC turning, forming, twisting, and bending. We use modern milling machines, and the entire process is overseen by fully trained programmers with expert knowledge and extensive experience. Along with quality control, careful preparation for the machining process, and minimizing material losses, we ensure the highest quality CNC milling and machining services.

If you have any questions, feel free to contact us at sales@electris.com