Three linear axes. Or five coordinated. Complexity decides.

Break-even is typically 3 setups on 3-axis. If a part requires 3+ setups on 3-axis, consolidating to 1–2 setups on 5-axis usually wins on total cost despite higher hourly rate. For parts needing 5+ setups on 3-axis, 5-axis is 30–50% cheaper total. For simple parts, 3-axis is cheaper. Our quote compares both approaches when applicable.

3+2 positional: rotary axes lock at a fixed angle, then 3-axis machining proceeds. Useful for accessing angled features without continuous rotation. Simultaneous 5-axis: all five axes move together during the cut. Required for continuous curved surfaces (impeller blades, airfoils). Our machines do both. 3+2 is simpler CAM; simultaneous requires more programming skill and slower feeds.

Typical aerospace bracket requiring 5 setups on 3-axis: each setup introduces ±0.03 mm position error. After 5 setups, accumulated error can reach ±0.15 mm between features — exceeding drawing requirements. Same part on 5-axis in 1 setup: all features referenced to one datum, ±0.01 mm relationships maintained. For drawing tolerances below ±0.05 mm between features in different orientations, 5-axis often mandatory.

Our 5-axis envelope: up to 800 × 800 × 600 mm work volume (DMG Mori DMU 80 P). Common part sizes 20 mm to 500 mm. Smaller parts (10 mm or less) better on Swiss-type turning with live tooling. Very large parts (> 800 mm) require multi-part fabrication or partner shop with larger 5-axis.

3-axis: CAM programming 1–3 hours per typical part. 5-axis: 3–8 hours typical, up to 20+ hours for complex impellers. Why: simultaneous multi-axis motion requires advanced CAM expertise, collision checking, tool-axis planning. This is why 5-axis is usually reserved for parts that genuinely benefit. Programming overhead is often 10–20% of 5-axis job cost for complex work.

Yes — 5-axis excels at injection mold and die work. Complex 3D surfaces, undercut features, parting lines all machined in single setup. Tool-axis tilt enables shorter, stiffer tools (better finish). Single-datum reference scheme reduces tolerance issues. For production mold work, 5-axis is increasingly the standard approach.