5 Axis CNC Machining: How To Choose For Your CNC Machining Parts | JS Precision

5 axis CNC machining is breaking down the limitations of complex part manufacturing.

Imagine a complex aero-engine impeller that normally takes three setups and several datum adjustments, now, all the surfaces, back sections, and base can be precisely machined within only one setup. This is not just a leap in terms of efficiency, but a revolution in terms of precision and design freedom.

Mastering the knowledge and utilization of 5-axis machining technology has become one of the key qualifications that help engineers and designers achieve the highest quality, the most complex geometries, and the shortest time to market.

This guide, led by experts from JS Precision, will take you deep into the world of 5 axis CNC and show how it might be the ultimate solution to manufacture complex parts.

Overview Core Answer

Comparison Dimensions	3-Axis CNC Machining	5-Axis CNC Machining	Core Value It Brings
Machining Principle	The tool travels along three linear axes: X, Y, and Z.	Adding A/B rotary axes to 3-axis machining to achieve five-axis linkage.	Allows for approaching the workpiece from any angle, achieving geometric freedom.
Clamping Method	The complex parts need several clampings and datum conversions.	The one-time clamping finishes most of the machining.	Reduces error accumulation and ensures ultra-high precision.
Applicable Parts	Prismatic, relatively simple parts.	Complex curved surfaces, deep cavities, and irregularly shaped parts.	Unlocks unprecedented design possibilities.
Cost Structure	The cost of equipment and labor is lower, while the secondary clamping cost is higher.	5 axis CNC machine price and programming cost higher, single-clamping efficiency extremely high.	The overall manufacturing cost for the complex part could be lower.
Best Application	Sheet metal parts, bases, simple prototypes.	Aerospace, medical implants, automotive engines, precision molds.	JS Precision helps you overcome the top manufacturing challenges.

How To Choose 5 axis CNC Machining? JS Precision Analyzes Key Decision Points

Practical experience plays a core role in the correct delivery of 5 axis CNC machining. JS Precision has been involved deeply in this field for more than 10 years and provides services with high-end 5-axis machining centers, including DMG MORI, for more than 500 clients across the aerospace, medical, and drone sectors.

We have completed complex parts machining, such as titanium alloy impellers with a tolerance of ±0.015mm and carbon fiber medical stents. The carbon fiber medical stent manufacturing process follows the requirements of the US Food and Drug Administration (FDA) for special process validation in 21 CFR 820.70 of the Medical Device Quality System Regulations.

We familiar with the machining characteristics of 7075 aluminum and Ti6Al4V, we help clients optimize multi-component welded parts into single-piece machining and save up to 30% in cost.

This is a comprehensive manual summarizing our years of project experience, including key points such as the selection of technology and cost control, helping you to avoid the pitfalls and make reliable decisions.

Want to check if your parts are suitable for 5 axis CNC machining? After submitting the basic information of your parts to JS Precision, our engineers will give a free preliminary assessment to help you clarify your selection direction.

What Is 5 Axis CNC Machining? Beyond Traditional Manufacturing

5 axis CNC machining is an advanced state-of-the-art CNC machining technology capable of achieving multi-directional and complex machining using co-ordination of the use of three linear axes: X, Y, and Z, and two rotary axes: A and B, or C.

Compared to the traditional 3-axis machining, it upgrades from "single-sided machining" to "omnidirectional machining," which changes the very root of the manufacturing model for complicated parts.

More Than Just 5 Directions: Understanding the Essence of "Linkage"

The core of 5-axis machining is in "linkage," including five motion axes:

• X-axis: Horizontal movement - left-right
• Y-axis: Horizontal motion back-forward
• Z-axis: Vertical movement (up-down)
• A-axis: Rotation around X-axis, normally workpiece rotation
• B/C axes: Rotation around the Y-axis (B-axis) or Z-axis (C-axis) (usually table or spindle rotation)

"Five-axis linkage" refers to the simultaneous movement of all five axes, allowing for continuous machining of complex curved surfaces such as impellers and mold cavities.

The "3+2 axis positioning" fixes the workpiece at a certain angle using the A, B/C axes first and then uses the X, Y, and Z axes for machining, suitable for multi-faceted parts like housings with angled holes. The application scenarios differ a lot between these two.

Why Is It the "Chosen One" for Complex Parts?

5 axis CNC machining naturally solves three major challenges of traditional machining:

• Complex Geometry: Parts do not need to be dismantled, direct machining of continuous curved surfaces and irregular structures avoids splicing errors.
• Deep Cavity Machining: The rotary axis adjusts the workpiece angle, allowing the tool to go deep inside the cavity wall for machining, and eliminates the need for tool lengthening.
• Interference Avoidance: By coordinated movement of axes, interference between tool, workpiece, and fixture is avoided, thereby reducing risks during machining.

Figure 1: Five axis CNC machining refers to a machining method in which cutting tools move along five different axes simultaneously.

Revealing: How Does 5 Axis CNC Achieve Revolutionary "One-Time Clamping"?

The core advantages of 5 axis CNC include "one-time clamping". By making use of the coherent operation of a rotary table and several axes, all the surfaces of a part can be machined in one clamping, which can change the traditional multi-clamping model fundamentally and influence the accuracy, efficiency, and cost greatly.

Rotary Table: From Multiple Faces to "No Dead Angles"

In that case, the workpiece can rotate around its A, B/C axes by using the rotary table. The angle range is generally from -120° to 120°, and it works like a "flexible robotic arm."

Compared to a traditional 3-axis machining setup, three separate clamping operations are usually required when performing multi-directional angled holes on a box-shaped part. A 5 axis CNC rotary table allows adjustment to the workpiece angle, so that it enables the tool to approach the workpiece from multiple directions, including the front, side, and top, without manual rotation.

Key To A Leap In Precision: Eliminating Datum Conversion Errors

Traditional multi-clamping introduces "datum conversion errors." Every clamping requires resetting the datum, and errors accumulate with each clamping. Normally, every clamping has an accumulation error of about 0.05mm.

A 5 axis CNC machine can be set up for a single clamping. It requires only one setting of the datum, and all machining is done with reference to this datum. This completely avoids datum conversion errors and ensures relative positional accuracy for critical features such as holes and contours of curved surfaces.

For example,when machining medical implants, tolerance for holes on different surfaces can be controlled within ±0.02mm.

Figure 2: Five axis machining simplifies the production process by achieving synchronous movement of five axes, reducing the need for multiple clamping.

How To Choose The Best Material For Your 5 Axis CNC Machining Project?

Material selection is critical to the success of a 5 axis CNC machining project. The machining characteristics of different materials can differ quite dramatically. JS Precision is familiar with the machining points of various materials and can match you up with the best material solution.

King of Metals: Aerospace-Grade Aluminum and Titanium Alloys

Aerospace Aluminum Alloys (like 7075 aluminum) and Titanium Alloys (like Ti6Al4V) are among the most common metal workpiece materials in 5 axis CNC machining. When processing these types of materials, 5-axis machining holds an apparent advantage:

• 7075 Aluminum: High strength, lightweight, tensile strength approximately 570MPa. 5-axis machining can precisely control its complex surface, making it suitable for drone parts and aircraft brackets.
• Titanium alloy Ti6Al4V: Corrosion and high temperature resistant. Through high-speed cutting and cooling synergies of 5-axis machining, avoid deformation during processing, suitable for implantable medical and aero-engine parts.

Engineering Plastics and Composites: From PEEK to Carbon Fiber

Engineering plastics, like PEEK, and composites, such as carbon fiber, have extensive application in medical and high-end fields. When doing 5 axis CNC machining of these materials, the following should be considered:

• PEEK: High-temperature resistant (continuous operating temperature 260℃), good biocompatibility. Cutting speed must be controlled during machining (recommended. 300-500m/min), in order to avoid material melting.
• Carbon fiber: high strength, light in weight, and during processing it needs special cutting tools, such as diamond tools to avoid delamination, for applications in medical stents and high-end equipment housings.

Material Type	Representative Material	Properties	Applicable Fields	5-Axis Machining Key Points
Aerospace Metal	7075 Aluminum	High strength, light weight.	Drone parts, aircraft stents.	Control cutting speed to avoid deformation.
Aerospace Metal	Ti6Al4V Titanium Alloy	Corrosion resistant, high temperature Resistant.	Medical implants, engine parts.	High-speed cutting + cooling synergy.
Engineering Plastic	PEEK	High temperature-resistant, biocompatible.	Medical parts, precision components.	Control speed, prevent melting.
Composite Material	Carbon Fiber	High strength, lightweight.	Medical stents, high-end equipment.	Specialized cutting tools, prevent delamination.

Smart Design To Optimize Your 5 Axis CNC Part Costs: Three Strategies

The cost for 5 axis CNC machining can be greatly reduced by optimizing parts from the design stage. JS Precision summarizes three practical ways to help you control your budget yet meet your performance needs.

Strategy 1: Avoid Deep Cavities and Long Overhangs

Deep cavities, with a depth over 3 times the diameter, and long overhangs, with tool extension over 5 times the diameter, increase machining difficulty:

• Special extended tools are required, which are 50-100% more expensive than ordinary tools.
• Low rigidity of the tool can cause vibration, thus reducing machining efficiency by more than 30%.
• Difficulty in controlling accuracy may result in multiple reworks, involving increased time costs.

Strategy 2: Standardize Internal Corner Radius

Irregular internal corner radii increase tool change frequency:

• Every tool change needs resetting and adjustment, which takes about 15-30 minutes.
• Standardized radii, such as all set to R1.5, reduce the tool types and save much machining time, thereby reducing machining costs by 20%-30%.

Strategy 3: Understand "5-Axis Friendly" Draft Angles

Even with strong 5-axis machining capability, an appropriate draft angle (recommended 1 ° -3 °) still has advantages:

• Reduced tool-workpiece friction allows improved surface quality, while roughness can be decreased from Ra1.6 down to Ra0.8
• Reduced cutting resistance, extending tool life and reducing tool change costs.

Figure 3: Avoiding deep hole machining in CNC design is not only a good process specification, but also the key to controlling costs and ensuring manufacturing consistency.

3 Axis Vs 5 Axis CNC: The Ultimate Showdown Of Precision And Capability

The selection of 3-axis vs 5-axis CNC influences the part machining effect directly. There is a huge difference between the two regarding machining capability and precision. Understanding their application limits helps you make the right choice.

The undisputed king of precision: why does 5-axis win at the starting line?

One-time clamping is the core of the precision advantage that 5-axis machining holds.

• Traditional 3-axis machining processes involve multiple clampings, all introducing an error of approximately 0.05mm each, which adds up and makes it difficult to guarantee precision.
• One-time clamping of 5-axis machining can control the tolerance of aluminum alloy parts within ±0.025mm and titanium alloy parts within ±0.03mm.

For example, when machining a gearbox with inclined holes, the hole tolerance after 3-axis machining may reach ±0.1mm, while 5-axis machining can control it to ±0.02mm, meeting high precision requirements.

Capability Gap: Some parts cannot be machined by 3-axis machining at all

The following two types of parts can only be machined by 5-axis machining:

• Undercuts: For example, in cases of housings with internal grooves, positions of grooves cannot be reached by a 3-axis tool. In 5-axis machining, by adjusting the angle of the rotation axis, the tool can go deeper into the groove.
• Continuous complex curved surfaces: Such as impellers and propellers, 3-axis machining. Machining on a single axis requires splitting multiple surfaces, leaving splicing marks. 5 axis CNC allows for continuous machining to ensure smooth surfaces.

Comparison Dimensions	3-axis CNC	5-axis CNC
Machining Capacity	Only one surface can be machined at any given time, undercuts and continuous complex surfaces are not achievable.	All surfaces can be machined, and undercuts and continuous complex surfaces are achievable.
Clamping Times	Repeated clampings, about 2-5 times	One-time clamping
Tolerance Range	Standard ±0.05-0.1mm	Standard ±0.02-0.03mm
Applicable Parts	Simple structures, such as flat plates and straight hole parts.	Complex structures like impellers, medical implants, and drone parts.
Cost per Hour	Approximately $50-80	Approximately $100-150
Cost of Production(Complex Parts)	High (multiple clampings + rework)	Low (one-time clamping + no rework)

Want to find out if 3-axis vs 5-axis CNC is the best choice for your part? Contact JS Precision today and let us recommend the most cost-effective solution for your parts' complexity and precision.

Core Equipment Unveiled: How To Choose Tools For Your 5 Axis Machining Center?

Compared with traditional equipment, tool requirements are far higher for 5 axis machining center. Proper tool selection can improve machining accuracy and efficiency. JS Precision has rich experience in choosing tools and is able to provide professional advice for you.

The Value of Short Tapered Tool Holders: Rigidity and Vibration Control

Short, tapered tool holders (like HSK and CAPTO tool holders) are ideal for 5 axis machining centers.

• The traditional BT tool holders incorporate a long taper that can easily generate vibration during high-dynamic movement, hence affecting accuracy.
• HSK tool holders have a short taper (typically 1:10), a large contact area with the spindle, stronger rigidity, and can reduce vibration by over 90%.
• CAPTO tool holder adopts polygonal interface, with higher positioning accuracy (repeated positioning accuracy ± 0.001mm), suitable for high-precision machining.

The Art of Balancing Tool Length and Diameter

In 5 axis CNC machining, the balance between tool length and diameter has a direct impact on the machining effect:

• A tool that is too long-more than 5 times the diameter-is not rigid and will vibrate. Whenever possible, reduce the tool length to the shortest possible for the work to be machined.
• Too large of a tool diameter could interfere with parts and fixtures. It is recommended to choose the diameter depending on the space of the machining area, and use long-neck tools if necessary.

Want to select tools for your 5 axis machining center? Please inform JS Precision of your machining materials and part structure, and we will recommend suitable tool holders and tool models to control the 5 axis CNC machine price while helping you improve machining stability.

Case Study: 5 Axis CNC Helps Reduce Drone Servo Mount Weight By 40%

Customer Pain Points

A drone company needed a high-strength, lightweight metal servo mount. The existing 3-axis solution had two major problems:

• The part was welded from three components and weighed 200g, which affected the drone flight time.
• The weld joints were low in strength, easily causing breakage during high-altitude flight and leading to poor reliability.

JS Precision Solution

• The first step is DFM optimization. Our engineers restructured the original 3-component design into a unified, topology-optimized structure, removing redundant materials and retaining critical stress areas.
• The second step is 5-axis machining. Using a DMG MORI 5 axis machining center, paired with HSK toolholders and carbide tools, we completed precision 5 axis CNC machining of all complex surfaces and lightweight cavities in a single setup, with real-time accuracy monitoring via machine measurement.

Our Success Result

The final product weighed only 120g, 40% lighter than the original solution. Tensile testing showed a 15% increase in structural strength, completely eliminating welding fracture issues.

Simultaneously, the reduced number of assembly steps increased production efficiency by 50%, shortening parts delivery time from 10 days to 5 days, helping the customer to successfully extend the flight range by 25%.

Want to replicate similar weight reduction and efficiency improvement cases? Submit your parts requirements to JS Precision immediately, and our online CNC service will help you achieve product upgrades.

Figure 4: CNC metal drone servo bracket

Manufacturing of Complex Parts: JS Precision's 5 Axis CNC Machining Services Throughout The Entire Process

JS Precision's 5-axis CNC machining services cover the entire process from drawings to finished products, with professional control at every stage to ensure efficient and precise project delivery.

Step 1: DFM Analysis – Your Free Design Optimization Consultant

Before giving a quote, our DFM engineers will provide a thorough examination of the part drawings you supply:

• Check the design for machining difficulties such as excessively deep cavities, excessively small fillets
• Optimisation suggestions, such as standardizing fillet radii, adjusting draft angles.
• Evaluate the rationality of material selection to help you reduce costs.

This step is absolutely free and helps you avoid possible risks before machining, it can save you from rework caused by a design fault.

Step 2: Precision Programming – A Perfect Preview of the Digital World

The programming phase uses professional CAM software, such as Mastercam. Engineers will execute the following three major tasks:

• Toolpath Planning: Determining the best path based on the part structure with the idea of reducing idle time and enhancing efficiency.
• Collision Detection: The ability to simulate the machining process in a virtual environment to detect any possible risk of collision between the tool and part/fixture, and make necessary adjustments in advance.
• Parameter Setting: Setting the cutting speed and feed rate according to the properties of materials. For example, in the case of machining Ti6Al4V titanium alloy, the cutting speed is set at 80-120 m/min.

Step 3: In-Machine Measurement – ​​Quality Protection During Machining

All 5 axis machining centers feature an integrated high-precision probe system:

• After the first piece is machined, the probe automatically detects key dimensions, such as hole diameter and surface contour, and compares them with the design values.
• If there are minor errors, the system will automatically compensate for the toolpath in order for the succession of parts to have consistent accuracy.
• The procedure also involves periodic sampling inspections during the process to avoid batch defects.

Want to try JS Precision's 5-axis CNC machining services? Please upload your part drawings to enjoy the full-process service that we offer, from DFM analysis to delivering the finished product, completely transparent and controllable.

FAQs

Q1: What is the minimum tolerance that can be achieved by 5-axis CNC machining?

At JS Precision, relying on a high-end 5 axis machining center and a temperature-controlled workshop, we can achieve ±0.025mm for aluminum alloy parts and ±0.03mm for titanium alloy parts. For special requirements, we can achieve up to ±0.015mm.

Q2: What types of parts are suitable for 5-axis CNC machining?

It can be best applied to parts with complex curved surfaces, deep cavities, oblique holes, or parts that need to perform multi-faceted machining in one molding process, such as impellers, medical implants, complicated drone supports, and precision mold cavities.

Q3: Is the cost of 5-axis CNC machining significantly higher than 3-axis?

Well, the hourly rate for 5-axis is higher, roughly in the range of $100-150 and for 3-axis, it is $50-80. However, with more complicated parts, the total cost of the part can be up to 20-30% less due to less clamping and fixtures, and fewer secondary operations, but with simple parts, 3-axis machining is more economical.

Q4: What is the difference between "3+2" machining and "5-axis simultaneous machining"?

"3+2" means first finding the angle then machining with 3 axes. It's suitable for polyhedral parts. "5-axis simultaneous machining" means all 5 axes are moving at the same time, suitable for parts that are continuous complex curved surfaces. JS Precision will offer both machining modes.

Q5: What file formats do you support?

Yes, we support all major formats including STEP, IGES, SLDPRT, X_T and PARASOLID. We prefer STEP format for its good compatibility.

Q6: What is the lead time for a typical part from quotation to delivery?

For standard materials like 7075 aluminum and PEEK, the prototyping stage will take 3-5 working days, while small-batch productions comprising 10-50 pieces will take about 7-10 working days. We will provide a clear delivery date.

Q7: What are the post-processing operations the 5-axis CNC machine can do?

We offer a full range of post-processing services including anodizing, sandblasting, electroplating, painting, and laser engraving. This enables one-stop delivery from machining to post-processing without you needing to deal with multiple suppliers.

Q8: How do you ensure the quality during machining?

All first-piece and process inspections are done with in-machine probes, and a CMM is also available for final verification of quality to ensure every part in production meets the design criteria.

Q9: Why choose JS Precision as your 5-axis CNC service provider?

Backed with high-end DMG MORI facilities, a team of engineers with over 10 years' experience in this industry, a rigorous quality control system, and convenient online service, we can offer you reliable 5-axis CNC machining services.

Summary

5-axis CNC machining has given manufacturing capability new, previously unimaginable heights. It's not an "advanced option" anymore, it is a core technology in dealing with modern engineering challenges in pursuit of product innovation and performance breakthroughs.

With more than 10 years of experience, high-end equipment, and end-to-end online CNC service, JS Precision will help to solve the problem in machining complex parts, ranging from weight reduction to efficiency improvement, from precision assurance for truly empowering your product with 5-axis machining.

Don't let the complicated designs remain on paper.

Now, come to JS Precision's online CNC service platform, upload your 3D file, and experience professional, fast, and transparent 5 axis CNC machining services. Get an instant quote in 30 seconds and make the next great idea become a reality!