CNC routing is the first choice for many manufacturers when it comes to engraving, 3D carving, reaming, and pocketing. The machine offers unparalleled quality which makes them suitable for various industrial applications. Of all types of CNC routers available, 3-axis and 5-axis are the most common. They have distinct capabilities and unique differences.
As a beginner or seasoned manufacturer, it is important to understand how 3-axis and 5-axis CNC routers work before using any to avoid mistakes. In this article, we have explained what 3-axis and 5-axis CNC routers are, and the major 3-axis vs 5-axis CNC router differences.
What is 3 Axis CNC Router
3-axis CNC routers are simple machines that make precision cuts to shape different types of materials. The router moves in predetermined directions across the surface of the workpiece along three linear axes; X, Y, and Z. X and Y axes represent horizontal left to right and front and back movements respectively. Furthermore, the Z axis is a vertical up-and-down motion. 3-axis CNC routers work mainly with soft metals, plastics, and composites. You can use them to cut, mill, engrave, and drill precise holes.
Pros and Cons Of 3-Axis CNC Routers
3-axis CNC routers are the most common type available. Many hobbyists and engineers opt for it because of its many properties. Let’s look at some advantages and disadvantages you will get from using a 3-axis CNC router.
- Ease of Use
Simplicity is one of the leading benefits of a 3-axis CNC router. The machine has an intuitive interface and you will find it easy to use. You do not need to have advanced machining skills to create accurate and high-quality cuts. You can use this machine for straightforward and less complex projects without mistakes.
- Low Cost
3-axis CNC routers come with a relatively low cost. The machine is affordable and has a low initial cost. You do not have to invest heavily to install the machine and get it running. Furthermore, it saves costs when it comes to energy. The energy needed to run the machine and make complex components is low.
- Simple Programming
Another benefit of a 3-axis CNC router is its simple programming features. Its limited range of movement allows you to generate G code without wasting too much time. You easily define the tool paths and simulate machining operations.
- Low Maintenance
3-axis CNC routers have lower maintenance needs. Daily and routine maintenance is simplified because the machine does not have many movable parts. 3-axis CNC routers do not wear easily and you don’t have to frequently replace their parts. All these further reduce the cost of operation.
Despite the benefits of 3-axis CNC routers, they come with some shortcomings you should be aware of. The following are some limitations of a 3-axis CNC router
- Limited Capabilities
3-axis CNC routers are reserved for 2D or 2.5D geometries. They are perfect for plane shapes that do not have complex features. When the complexity of the part increases, 3-axis CNC routers begin to lose their relevance. It may be challenging to work on highly detailed components.
- Multiple Setup
For complex projects, you may need two or more set up for an effective cutting action. The tool can only work on one side of the workpiece at a time. Furthermore, you may have to manually reposition the part when machining multiple sides. This is a serious limitation as it increases the risk of errors and production time.
What is 5 Axis CNC Router
5-axis CNC routers are the most sophisticated multi-axis machines available. They move in five different directions to hollow a part of the workpiece and create various shapes. In addition to three linear axes X, Y, and Z, the machine has two additional rotary axes; A and B. The A axis signifies rotation around the X axis while the B axis moves around the Y axis. Furthermore, 5-axis CNC routers come with more freedom of movement and have a precision limit of +/- 0.0025 mm. This machine is versatile and you can use it for milling, drilling, and cutting operations.
Pros and Cons of 5-Axis CNC Router
5-axis CNC routers are slowly taking over the manufacturing sectors. They are the first choice for many part manufacturers because of their unwavering precision. Here are the major benefits and limitations of a 5-axis CNC router
- Accuracy
The accuracy of the 5-axis CNC routing operation is unmatched. The reasons behind this are not far-fetched. You don’t need to set the machine up multiple times for an optimal cutting process. This prevents the introduction of errors that can affect precision and repeatability.
- Speed
The speed of 5-axis CNC routers is second to none. Their high fee rate and spindle speed allow for faster machining of components. The machine can run unattended for hours to produce many parts in a short time. This increases production efficiency as you can carry out other important activities.
- Complex Shapes
A leading benefit of 5-axis CNC routers is their ability to machine complex shapes. The workpiece remains stationary while the routing tools can attack from different angles to carve complex arcs. You do this in a single setup and without any form of manual intervention.
- Quality Finish
5-axis CNC routers create parts with a good surface finish that may not require further processing. You have precise control over the process to produce more consistent cuts. Furthermore, the different axes of motion this machine comes with bring the tool closer to the workpiece. Shorter tools are more rigid and produce a high-quality finish.
The following are some limitations of 5-axis CNC routers
- Cost
5-axis CNC routers are generally more pricey. They are expensive to set up and operate. The machines consume more energy and you need advanced software to carry out an operation. The good news is the unit cost of operating reduces as production volume increases.
- Operator Training
You must have the necessary skills and expertise to use a 5-axis CNC router. This machine comes with more complex programming that may be difficult for novices to navigate through. You should possess basic mathematical skills and software training to avoid mistakes.
3 Axis vs 5 Axis CNC Router: How to Choose
3-axis and 5-axis CNC routers are different in many aspects which affects their applications. Choosing the most appropriate for your project requires an in-depth understanding of their differences. Let’s look at the ways 3-axis and 5-axis CNC routers differ
- Capabilities
The range of movement of the cutting tools is a major difference between the 3-axis and 5-axis CNC routers. 3-axis CNC is restricted to linear axes motion. This makes it ideal for simple shapes and geometries. On the other hand, 5-axis CNC routers move linearly and rotationally. You can use them for three-dimensional shapes and contours.
- Ease of Programming
You can also differentiate between 3-axis and 5-axis CNC based on how easy it is to program the machine. It is easy and more straightforward to program 3-axis CNC routers and get them running. For their counterpart, you will need advanced technical knowledge and more sophisticated CAM software.
- Accuracy and Precision
3-axis and 5-axis CNC routers also differ in terms of accuracy and precision. 3-axis CNC routers come with a lower degree of precision. You should go for it when working on applications with a flexible tolerance limit. However, the parts made using 5-axis CNC routers are accurate and repeatable. They have increased freedom of movement and you may not need to further process the final parts.
- Speed
The time taken to machine parts with both machine types is also different. 5-axis CNC routers are faster and produce complex parts at a higher speed. This can be attributed to the movement flexibility this machine has. For this reason, 5-axis CNC routers are better for medium to large-scale production.
- Cost
The total cost of running 3-axis CNC and 5-axis CNC routers is another means of differentiation. 3-axis CNC routers are more affordable. They are cheaper to buy, install, and program. On the other hand, the cost of a 5-axis CNC router is on the high side. They have advanced features and capabilities,
- Skill and Expertise
The level of skill and expertise to run a 3-axis CNC router is different from that of a 5-axis. You need basic CNC knowledge and calculation skills. For 5-axis CNC routers, you must have a deep understanding of programming and years of experience to avoid errors.
- Maintenance Needs
Another difference between 3-axis and 5-axis CNC routers is the maintenance needs. 3-axis machines have less movable parts and are easier to clean and maintain. 5-axis CNC, on the other hand, has more maintenance requirements. They need more rigorous maintenance which comes with higher costs.
Applications
The applications of 3-axis is different from that of 5-axis CNC routers. 3-axis CNC routers thrive in places where simple shapes and geometries are required. You can use them for woodworking, plastic fabrication, and sign making. However, 5-axis CNC routers have applications in mold and die making, decorative panels, automotive parts, and structural components for buildings.
| Parameters | 3-Axis CNC Router | 5-Axis CNC Router |
| Capabilities | Movement is confined to only linear axes. | The tools move in both linear and rotational directions. |
| Part Complexity | 2D or 2.5D shapes. | 3D geometries. |
| Ease of Programming | Simple to programming. | Programming requires technical expertise. |
| Accuracy and Precision | Good. | Excellent. |
| Speed | Fast for simple shapes | Machines complex shapes at a high speed. |
| Costs | Low cost of purchase and set up. | More expensive to install and use. |
| Skill and Expertise | Basic CNC knowledge. | Advanced CNC knowledge. |
| Maintenance Needs | Low. | High. |
| Applications | Woodworking, plastic fabrication, and sign making. | Mold and die making, decorative panels, automotive parts, and structural components for buildings. |
Table 1: 3-axis vs 5-axis CNC routers differences at a glance.
Conclusion
Though the demand for 5-axis CNC routers is increasing daily, the 3-axis type is still in vogue because of its benefits. To prevent detrimental mistakes, you have to understand the differences between both machines before using any. Several factors including part complexity, production volume, and tolerance limit will influence your choice. You should also consider skill requirements and budget. If you are still unsure about the type of machine to use, reach out to a reliable CNC routing service provider to get more answers.