Tag: Kimla CNC Router

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CNC Routing: Composite Decking Boards

CNC Routing Composite Decking Boards 5

Composite decking boards were first developed in the late 1980s and early 1990s as an eco-friendly, low-maintenance alternative to traditional wood decking. Pioneered by companies like Trex, the earliest composite boards were made from a simple blend of wood fibers (or wood flour) and plastic (usually recycled polyethylene, polypropylene, or PVC), offering resistance to rot and insects, but often prone to fading, staining, and mold. In the mid-2000s, the industry introduced second-generation “capped” composites—boards with a protective polymer shell—significantly improving durability and aesthetics. Over time, manufacturers refined the materials and processes, leading to more realistic wood-like textures, improved resistance to the elements, and a greater emphasis on sustainability by using high percentages of recycled materials. Today, composite decking has become a popular and long-lasting choice for outdoor spaces, valued for its low upkeep and environmental benefits.

With the mixture of plastics and wood fibers, the question “how do I cut this?” comes up often. The easy answer is, with a CNC router bit of course! Choosing the correct one is the hard part which is exactly why I write these articles. We like to scrap chip-load calculators, throw any and every tool at a specific material, then optimize the best performing one.

Thanks to the CNC routers from Specialty Machinery Inc., we were able to do testing on both their Specialty Cutting Systems Legacy router as well as the Kimla Regency router with the exclusive MagLev™ technology.

Depending on the composite decking board thickness, you can choose the Razor Series tool diameter that fits your needs. In this case, we cut 1/2″ decking with a 1/4″ 3 Flute Spiral Upcut endmill called the XR2062-CB. This tool is meant to cut fast without sacrificing edge quality, and it did just that.

This tool optimized out at 200-300 IPM, 21,000 RPM, Climb Cut, at 2 passes. The 3/8″ version of this tool was able to cut it in one pass. The edge quality came out great and the speed was unmatched by any other tool. The Razor series bits were invented to cut Corian material (see our article on Corian material) but they do a phenomenal job with plastics and foams as well. In second place, the Omega Series cut these boards with great quality but at a lower feed rate.

Quick Facts

  • Endmills: Razor Series
  • Specific Tool: XR2062-CB
  • Spindle Speed: 21,000 RPM
  • Feed Rate: 200-300 IPM
  • Direction: Climb
  • Number of Passes: 1 to 1.5 times the diameter of the tool
Greg Smolka

Greg Smolka (Author)

CNC Tooling & Applications Manager

Here to help with tooling recommendations (bits, knives, collets, tool holders, maintenance kits, torque stations, etc.) and applications (feeds/speeds, tips/tricks, # of passes, etc.).

Contact Info: greg@cnctoolingshop.com | (616) 502-7277 | LinkedIn

If you have any questions about which tools to use for your project as well as how to program them for success, feel free to reach out anytime. Thanks for reading!

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CNC Routing: 6061 Aluminum

CNC Routing 6061 Aluminum

If you own a CNC router, chances are, you have or have thought about cutting aluminum. Whether it be for signs, fabrication parts, automotive, or something else, learning to cut aluminum is a great skill to have. Today, we dive into cutting 1/2″ 6061 Aluminum on a Kimla BPF CNC Router with a 3/8″ Two Flute Upspiral Bit and Alcohol-Based Misting Fluid. CNC Routing: 6061 Aluminum

First off, let’s dive into Aluminum and what to know. The grade of aluminum changes everything! Softer grades, such as 3003 series, needs to be cut at a slower feed rate and most commonly with a single flute CNC bit. Higher grades, such as 6061 series, needs to be cut at higher feed rates and can handle a CNC bit with more than one flute.

Misting fluid is a necessity, not a choice! Whether you’re using an alcohol-based or veggie-based fluid, do not skip this step. There are of course exceptions to this rule, like any, but most of time it is absolutely a requirement. The friction produced from carbide endmills cutting through aluminum sheets, generates heat. Heat is the enemy, which is why misting fluid is so important.

Lastly, material hold-down changes everything. This is important for cutting any material but even more when it comes to aluminum. When parts are not held down properly, it causes chatter, which generates more heat and in turn decreases quality as well as the life of the bits being used.

6061 Aluminum

Type of CNC Router

For this project, we used the Kimla BPF Router. Kimla CNC Routers are currently the hottest routers on the market. They’re in a league of their own due to precise and intentional manufacturing. Customer needs are always at the forefront, which is why we have no problem recommending them to any and everyone. If you’d like to learn more about the Kimla machine line, reach out to Specialty Machinery Inc.

For the most part, Aluminum is cut on a CNC router with a few select CNC bits. We found that the best bit for high speed and top-notch quality on 1/2″ 6061 aluminum was the XV2033 and pairing it with Liquid X, a misting fluid by X-Edge Tools. The XV2033 is a 3/8″ two flute up-spiral tool made for cutting aluminum with a 5052 series grade or higher. The extra flute allows for feed rates to be increased and the up-spiral direction provides great quality. Liquid X is alcohol-based which combats heat more intensely than veggie-based versions and our go-to misting fluid at CNC Tooling Shop.

CNC Routing: 6061 Aluminum

For this project, a full cut-through was all that was needed. We could have drilled holes, beveled edges, or something else but we chose to focus on quality and precision. Our goal was to not only make jumbo puzzle pieces but to also have them fit together much tighter than a glove. We set the Liquid X misting fluid at a standard medium-spray aimed towards the flute of the bit as well as at the top of the material. Our feeds and speeds for the 3/8″ two flute up-spiral bit (XV2033) were set at 22,000 RPM and 150 IPM. For this tool, conventional direction is optimal. We also setup a sloping lead-in and cut through the 1/2″ in three passes to ensure high quality and precision.

Cleanup Pass

After this, we did a cleanup pass using the same bit (XV2033), shaving off an extra .03″ from the edge, to leave a clean finish. For the cleanup pass, we changed the feed rate to 75 IPM and left everything else the same. These parts came out phenomenal! They wouldn’t fit together unless they were perfectly leveled. Once leveled and pressed together, you could hold them all up together by only grabbing onto one of the pieces.

Feeds & Speeds

  • Cutout: XV2033 | Feed Rate: 150 IPM | Spindle Speed: 22,000 RPM | Direction: Climb | Passes: 3
  • Cleanup (.03″ Removal): XV2033 | Feed Rate: 75 IPM | Spindle Speed: 22,000 RPM | Direction: Climb | Passes: 1

Feel free to reach out with any questions or requests for tool recommendations for cutting 6061 aluminum, other grades of aluminum, plastics, composites, or woods.

Greg Smolka

Greg Smolka (Author)

CNC Tooling & Applications Manager

Here to help with tooling recommendations (bits, knives, collets, tool holders, maintenance kits, torque stations, etc.) and applications (feeds/speeds, tips/tricks, # of passes, etc.).

Contact Info: greg@cnctoolingshop.com | (616) 502-7277 | LinkedIn

XL001 LIQUID X

XL001 LIQUID X

$124.00

Misting fluid for assisting in the cutting of aluminum, steel composite materials, etc. by cooling down the cutting process and minimizing heat buildup.

SKU: XL001
Category: ,
Tags: , ,
XV2033 3/8"

XV2033 3/8″

$87.65

2 flute upspiral for ALUMINUM, ACM, WOOD, etc

SKU: XV2033
Category: , ,
Tags: , , , ,

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The Importance of CNC Routers in Modern Manufacturing

CNC routers have revolutionized the manufacturing and woodworking industries, bringing precision, efficiency, and versatility to various applications. As technology continues to advance, the significance of CNC routers only grows. This article explores the importance of CNC routers and their impact on modern production processes.

What is a CNC Router?

A CNC (Computer Numerical Control) router is a computer-controlled cutting machine that carves materials like wood, metal, plastic, and foam. By using a rotating bit, CNC routers can create intricate designs, shapes, and patterns with high precision. These machines can automate complex tasks, enhancing productivity and consistency.

Key Benefits of CNC Routers

1. Precision and Accuracy

CNC routers offer unmatched precision. The ability to execute complex designs with tight tolerances means that manufacturers can produce high-quality components consistently. This level of accuracy is essential in industries like aerospace, automotive, and cabinetry, where even minor deviations can lead to significant issues.

2. Increased Efficiency

Automating the cutting process with CNC routers significantly increases efficiency. These machines can operate continuously, allowing for rapid production runs and minimizing downtime. As a result, businesses can meet tight deadlines and scale operations without sacrificing quality.

3. Versatility

CNC routers are incredibly versatile. They can handle a wide range of materials and applications, from intricate wood carvings to metal fabrications and prototypes. This adaptability makes CNC routers a valuable asset across various industries, including furniture making, signage, and industrial manufacturing.

4. Reduced Labor Costs

While initial investments in CNC technology can be high, the long-term savings often outweigh the costs. By automating processes, companies can reduce labor costs and mitigate the risks associated with human error. This efficiency leads to lower production costs and increased profit margins.

5. Complex Design Capability

CNC routers enable designers and engineers to create complex shapes and patterns that would be nearly impossible to achieve with traditional methods. This capability opens up new avenues for creativity, allowing businesses to innovate and differentiate their products in the marketplace.

6. Improved Safety

CNC routers enhance workplace safety by minimizing manual handling and exposure to hazardous cutting tools. With automated processes, operators can focus on monitoring and maintaining the machine rather than performing risky manual operations.

Applications of CNC Routers

CNC routers find applications across numerous sectors, including:

  • Woodworking: Creating furniture, cabinetry, and intricate wood designs.
  • Sign Making: Producing detailed signage and promotional displays.
  • Automotive: Fabricating components and prototypes with precision.
  • Aerospace: Manufacturing lightweight and durable parts to stringent specifications.
  • Arts and Crafts: Allowing artisans to produce unique pieces with intricate details.

Conclusion

The importance of CNC routers in modern manufacturing cannot be overstated. With their precision, efficiency, and versatility, these machines have become essential tools in various industries. As technology continues to advance, CNC routers will likely evolve further, leading to even more innovative applications and benefits. Embracing CNC technology is crucial for businesses looking to stay competitive and meet the demands of today’s fast-paced market.