Save Money on Complex Low-Volume Parts with 5-Axis Machining

There’s a common assumption that highly complex parts with many features are expensive to machine in low-volume quantities. And that may be true at many precision machine shops, but it’s not the case here at Area Tool & Manufacturing, Inc. 

While other shops charge a premium for small production runs—preferring instead to pursue high-volume, high-cost customers—our team specializes in low-volume projects. We’ve made it our mission to machine complex parts quickly and cost-effectively—no minimum order requirements.

Our secret? Leveraging our Okuma GENOS M460V-5AX 5-axis machining center to reduce setups and maximize efficiency on our shop floor. 

5-Axis Machining at Area Tool & Manufacturing, Inc. 

Unlike standard 3 or 4-axis machines that may require several labor-intensive (and expensive!) setups to complete a complex part, 5-axis machines can often get the job done with a single setup. That saves our precision machine shop time, and we pass this benefit on to our customers in the form of lower costs and shorter lead times. 

How does 5-axis machining work? The 5-axis machining center shapes every facet of a workpiece with a cutting tool that spans the X, Y, and Z linear axes while simultaneously rotating on the A and B axes.

At Area Tool & Manufacturing, Inc., we use Okuma’s GENOS M460V-5AX, which produces high-precision parts with outstanding surface finishes and impressive metal removal rates.

We conducted substantial research before investing in this machine. One of the major highlights, in our opinion, is its ability to run like a standard 3-axis machine, applying extra axes to perform 3+2 machining. 

That means we can use our Okuma for simpler milling jobs in addition to complex parts that require 5-axis machining. We joke that we’ll never buy a 3-axis machine again—and it’s true. Why would we, when we can reliably use an Okuma to produce top-notch parts quickly and cost-effectively?

Benefit from Accuracy, Speed, and Affordability 

Whether you need 5-axis machining for a complex part or 3+2 axis machining for a simple part, you’ll benefit from our Okuma: 

Accuracy

When machining a part with tight tolerances that requires repeatability, accuracy is the top priority—and the biggest challenge. Every manual adjustment creates margin for error, and even slight inaccuracies can negatively impact the part’s function and longevity.

5-axis machining keeps human intervention to a minimum, ensuring accuracy and consistency from part to part.   

Speed

On a standard 3-axis machine, a part requiring five operations can absorb 2.5 hours in setup alone!

In contrast, our 5-axis machine grabs the part in one hold, then rotates and cuts as needed without additional setups. By investing more programming and setup time on the front-end of a job, we’re able to complete at least 80% of a part in a single setup.

This benefit expedites the entire precision machining process and reduces lead times for customers.

Affordability 

Many customers are intimidated when they hear mention of 5-axis machining because they associate it with high costs. But you’ll never incur additional fees for this capability when you work with us. The whole purpose of our Okuma is to fulfill low-volume orders with increased efficiency and affordability. 

Our shop welcomes the high-precision, low-volume work that many other shops penalize by charging considerable setup fees that don’t make sense for small jobs. 

As low-volume specialists, we recognize the value of 5-axis machining for reducing setup time, amplifying accuracy, streamlining our processes, and accelerating delivery timelines—regardless of order size.

At Area Tool & Manufacturing, Inc., we’re committed to quality, efficiency, and fast turnaround, and we invest in the tools and technologies necessary to get every job done right. Request a quote to work with us!