How to Successfully Cut Small Shapes Without Them Moving

PUBLISHED by EYE ON DESIGN

When it comes to CNC machining, cutting small shapes presents a unique challenge. The precision required to cut these shapes is only half the battle; ensuring they stay in place during the process is equally critical. Movement during cutting can ruin the final product, waste materials, and lead to machine downtime. So, how can you successfully cut small shapes without them moving? Let’s explore the solutions.

1. The Importance of Work holding

Effective work holding is the foundation of successful CNC cutting, especially for small shapes. Without proper stabilisation, vibrations or machine forces can cause even the most precise cuts to fail. Here are some proven work holding techniques:

Vacuum Beds:
Tekcel CNC routers are equipped with advanced vacuum systems designed to secure materials firmly in place. The suction force from these systems minimises movement, even for intricate, small-scale shapes. NB: Make sure your vacuum Pump Filters are cleaned and replaced regularly for optimum hold down efficiency
Sacrificial Layers:
Adding an MDF sacrificial layer beneath your material helps improve and spread hold-down pressure, which allows for over cutting depth without damaging your CNC bed. NB: regular skimming of your MDF sacrificial bed is essential for quality hold down and cutting performance.

2. Tooling Choices Make a Difference

The right tooling is essential for cutting small shapes. Using the wrong cutter can increase the chances of material movement. Tekcel’s CNC tooling range includes solutions designed for precision and stability

Single Flute Cutters:
Ideal for clean, precise cuts on a wide range of materials. These tools come in a variety of smaller diameters to reduce cutting forces, making them perfect for small shapes.
Specialised Cutters for Plastics and Metals:
Tools like the CP Single Flute for acrylic and DA Single Flute for aluminium help achieve smooth, clean, burr-free results, reducing the risk of the material shifting during operation.

3. Optimising Machine Settings

Even the best tools and work holding systems can fall short if your CNC router settings aren’t tuned correctly. To cut small shapes without movement:

Adjust Feed Rates and Spindle Speeds:
Slower feed rates and appropriate spindle speeds reduce cutting forces, minimising the chance of parts shifting.
Utilise Step-Down Cutting:
Layered cutting (e.g., onion skinning) keeps small pieces attached to the material sheet during most of the machining process, preventing them from moving prematurely.

4. Tekcel-Specific Solutions for Small Shape Cutting

Tekcel CNC routers excel at handling intricate cuts thanks to their robust design and precision engineering. Features that make Tekcel the ideal choice for small shapes include:

High-Performance Vacuum Systems:
Tekcel routers feature industrial-strength vacuum beds that hold materials securely, even when cutting detailed designs.
Onion Skin Cutting:
A Tekcel router can perform ultra-thin cuts that leave a sliver of material (the "onion skin") to hold parts in place until they’re fully cut out.
Cut-to-Print Systems:
The Tekcel OptiCam system ensures precision alignment when working with printed materials, ensuring that even small shapes are cut with absolute accuracy.

5. Pro Tips for Cutting Small Shapes

To further ensure success, consider these practical tips:

Use Tabs:
Tabs are small, intentional connections that hold the shape to the parent material during cutting. They can be easily removed afterward.
Double-Sided Adhesive:
For non-porous materials, adhesive-backed sheets add an extra layer of stability, preventing parts from shifting.
Nest Small Shapes Strategically:
Grouping small shapes close together during nesting reduces material waste and creates additional stability during cutting.
Lead In / Out:
Using the “Lead In / Lead Out” feature in your Cad/Cam software will enable the tool to blend in and blend out of the shape while cutting. This keeps the tool force to the waste piece of the material at the end of the shape and therefore preventing any potential movement

Tekcel-Specific Solutions for Small Shape Cutting

Conclusion

Cutting small shapes without movement is a challenge, but it’s entirely manageable with the right equipment, tools, and techniques. With a Tekcel CNC router, high-performance vacuum systems, and precision tooling, you can turn intricate designs into flawless products with ease.

Ready to optimise your workflow and achieve perfect results? Contact us today for expert advice, high-quality tooling, and cutting-edge Tekcel CNC routers.