How Material Choice Affects Machining Time and Part Cost

At Focused on Machining, we work with a wide range of materials, from aluminum to Inconel to A286. But one thing we always make clear to customers is that these materials differ not only in their performance, but also in their machinability. Material choice can directly impact factors like cycle time and tooling, ultimately driving part cost. 

Learn how the machining process changes, and why that leads to higher prices.

Why Material Choice Affects Machining Time

On the machinability spectrum, aluminum is relatively easy to cut, while Inconel machining is much more demanding. Aluminum allows for aggressive machining, but Inconel does not.

This is reflected in quotes, as machine shop pricing is closely tied to time. Longer machining time means higher cost. At Focused on Machining, price is heavily tied to production hours and shop rate. But other material factors do add to price, as well; for instance, materials like Inconel are significantly more expensive, while specialized tools may be needed because tool wear can be more severe.

Comparing Aluminum and Inconel on the Same Part

We have never machined the exact same part in both aluminum and Inconel, so a perfect one-to-one comparison is difficult. But a hypothetical example still helps illustrate the difference.

For this hypothetical, we considered machining a part that is 4” x 4” x 1” with a 0.5” end mill to rough it.

With aluminum, especially 6000 series aluminum, we can typically use tooling designed for high material removal rates. For a hypothetical part, that might mean a half-inch three-flute tool taking deep cuts at high RPMs and aggressive stepovers. Because aluminum is comparatively soft and easy to machine, we can remove material quickly and efficiently.

Inconel requires a much different approach. For the same part made of Inconel, we would likely use a five-flute or seven-flute tool with much more conservative cutting parameters. The depth of cut would be shallower and RPMs would be reduced. Additionally, heat control becomes critical with Inconel because of the potential for work hardening. 

Quantifying the Difference: A 17x Change

In qualitative terms, aluminum lets you cut fast, while Inconel forces you to slow down. But quantitatively, a simple back-of-the-envelope calculation suggests that machining the part from Inconel 718 would take roughly 17 times longer than machining the same part in 6061 aluminum. 

That’s just an estimate, but it certainly aligns with our general experience. A very simple part like this that might take minutes in aluminum could take close to an hour in Inconel. And that difference becomes especially important in our production machining services, when the gap multiplies significantly across hundreds or thousands of pieces. 

Experience Is Critical With Difficult Materials

When a project involves Inconel, A286, or other difficult materials, experience matters. An expert shop understands how to move as fast as possible without risking scrap and rework. 

At our precision machine shop, we have years of experience machining challenging materials. We understand the risks, and we know the best techniques to be as efficient as possible for our customers.

If you’re looking for Inconel, A286, or titanium machining, let’s discuss the best approach for your project. Contact us today!

A Case Study in 5-Axis Machining: Reducing Setups and Improving Lead Times

At Focused on Machining, our 5-axis machining is now running at full speed. As our team has gained experience with the new equipment, we have become more efficient in our manufacturing for 5-axis parts. 

5-axis machining is often associated with complex geometries, and it does allow us to machine challenging contours and other difficult features more effectively than many traditional setups. But in our shop, customers have also seen major benefits in speed, as well.

One recent manifold project is a strong example of how 5-axis machining can improve efficiency and help keep demanding jobs on schedule. 

A Complex Manifold With Tight Requirements

Focused on Machining has produced complex manifolds for years, and this recent project was an excellent example of the precision machining work we often do. The part was an aluminum block measuring roughly 2 inches by 2 inches by 12 inches, with 17 ports.

This manifold was part of our aerospace machining work for a customer. It was designed for fuel lines in a rocket engine, so positional accuracy was critical and the tolerance requirements on the holes were extremely tight. In fact, inspection did not stop at the physical surface of the part. We also had to project a feature location four inches out from the part and verify that it still met the required positional tolerance at that distance.

Before and After: Reduced Setups, Greater Efficiency

We originally quoted and planned this part before our 5-axis machine arrived, and at that point, we planned for the part on our existing equipment. Ultimately, though, we were able to machine it on our new 5-axis. That gives us a clear before-and-after comparison:

• If we had machined this manifold on our horizontal machine, it would have required four operations. 

• On a vertical machine, it would have taken at least seven operations. 

• On our 5-axis machine, we completed it in just two operations.

How Reduced Operations Benefit Customers

For those who aren’t in a machine shop every day, it’s worth explaining what these terms mean. An “operation” is essentially a separate setup or machining step. Each time a part has to be repositioned or moved so a different side or feature can be machined, that adds another operation.

Fewer operations benefit customers in multiple ways. First, every time a part is handled in a setup, it introduces the opportunity for error. Second, each additional setup adds labor and production time because the part must be reoriented and verified before machining continues. Third, longer cycle times within fewer setups can create opportunities for unattended lights-out machining, which can significantly improve throughput.

Lights-Out Manufacturing Led to Scheduling Flexibility

This job also involved substantial outside processing that we coordinated on the customer’s behalf, including chem film and precision cleaning. Because of those requirements, we had very little room for delay during machining.

Fortunately, the reduced number of setups made a major difference. Cycle times were nearly three hours, and the 5-axis machine is palletized, which allowed us to load multiple parts at once. Those factors let us run these parts for approximately six hours unattended at night. As a result, we kept the project moving and met its deadline.

Always Getting Better, Faster, and More Cost-Efficient

Our experience with 5-axis machining is leading to consistent improvements in efficiency. We’re already seeing shorter production times, and we expect the trend to continue. And over time, we know increased efficiency will help reduce costs for customers in our contract manufacturing services.

If you have a part that could benefit from 5-axis machining, let’s discuss. Whether the priority is part complexity or shorter lead times, Focused on Machining is ready to help. Contact us today!

A Colorado Contract Manufacturer Ready to Support Primes

At Focused on Machining, we’re proud to be located in Colorado, a state packed with significant aerospace and defense companies and institutions. This aerospace legacy is part of our own company’s history. Our history of partnerships with the industry allows us to understand how to support long-term programs for primes and OEMs in the region.

Rooted in Manufacturing History

Our shop sits on Titan Road in the Denver metro area, a name taken from aerospace history. It comes from the legendary Titan missiles built by the Martin Company, now part of Lockheed Martin. Today, just a few miles west of us, Lockheed Martin operates a facility where engineers work on cutting-edge aerospace projects. 

Many machine shops near us were founded in the 1970s for work tied to defense programs, and our own shop later grew out of that landscape.

A Region Full of Primes

Colorado is home to a remarkable number of major aerospace and defense primes and institutions. The ecosystem has grown over decades, and it’s part of what’s driven contract manufacturers like Focused on Machining to excel.

BAE Systems, Lockheed Martin, Raytheon, Northrop Grumman, and ULA all maintain a significant presence here. Ursa Major, a rocket propulsion company, is headquartered in Colorado. The University of Colorado’s Laboratory for Atmospheric and Space Physics, the Air Force Academy, and NORAD are all in our shop’s region.

The Advantages of a Local Defense Supplier

For Colorado primes managing complex programs, there are real benefits to partnering with us as a supplier. Having Focused on Machining nearby means:

• Faster audit visits: When you’re conducting in-house supplier audits, we’re a short drive away.

• Reduced shipping costs: Getting parts to and from our facility is straightforward and cost-effective.

• Rapid quality response: In the very rare cases that issues need to be resolved, we can talk in person on-site the same day.

• Direct engineering access: Face-to-face meetings with our team are possible without extensive scheduling for travel.

Certifications for Your Program Requirements

Of course, being local can be an added benefit, but only if a supplier can meet the necessary standards of aerospace machining.

At Focused on Machining, we have extensive capabilities that allow us to expertly serve primes. We hold AS9100D certification and ITAR registration, and we are currently CMMC Level 2 compliant, with our audit for full Level 2 certification scheduled for summer 2026. And our status as a Service-Disabled Veteran-Owned Small Business (SDVOSB) allows us to help primes fulfill supplier diversity and subcontracting goals.

Our advanced machining capabilities include 5-axis for complex geometries, and we work with demanding materials like Inconel. We have a history of supporting programs for primes including ULA and Lockheed Martin.

A Partner for Long-Term Programs

Whether you’re operating out of Colorado or looking for an expert partner across the country, we’re ready to be a qualified precision machining supplier for your repeat production work. Talk to us today about your aerospace and defense programs!

On-Time Delivery and Quality Ratings: Behind the Numbers in Aerospace & Defense Supply Chains

Many contract manufacturers talk about their on-time delivery rate and quality rating, but it’s important for primes and OEMs to know the story behind these numbers. At Focused on Machining, our on-time delivery rate is above 90% over the past 24 months, with a quality rating above 98%. But a deeper understanding of these metrics shows how a truly reliable supplier will differ from a partner that might sound good on paper.

On-Time Delivery Is Only Part of the Story

In high-stakes defense and aerospace programs, a single late part can delay an entire production line. For a large enough program, that could lead to millions of dollars lost. Primes have a lot at stake with on-time delivery, but the metric alone can’t always be enough to determine who can actually deliver.

Our on-time delivery rate for the past 24 months is above 90%, but there’s more to the number. When a delivery does miss its target date, the delay is typically days rather than weeks or months. That’s because we’ve invested in technology that allows us to make data-driven commitments at the start of every project.

Some shops may simply operate off of instinct, but our ERP system, ProShop, allows us to plan every step months ahead. We look at our machining schedule, outside processing time, shipping windows, and more. That lets us give you a reliable delivery date. And if we can’t meet your timeline, we’ll tell you upfront.

The Context for Quality Ratings

Of course, on-time delivery without consistent quality is a hollow number. Our high quality rating of 98% is the first step in proving our value in precision machining. But there’s still more to understand.

Of that remaining 2%, nearly every instance involves situations where we proactively and transparently reached out to a customer to discuss parts with small deviations from print. Yet after engineering review, the customer was ready to accept them.

For example, we recently machined a batch of 25 parts for an aerospace customer. Three of the parts came in technically outside tolerance, but within three ten-thousandths of an inch of the requirement. We proactively reached out to the customer to discuss their options: we could ship the full batch and allow them to inspect the three nonconforming parts, or we could take additional time to remake those three. The buyer’s engineering team chose the former option and accepted all 25 parts.

Stories like these make up most of the nonconformances that affect our quality rating, but in some ways we’re proud of them. We are able to warn customers of potential issues ahead of time and allow them to make informed decisions. We don’t hide from bad news.

As far as actual customer rejections for parts delivered out of spec, we’ve had a single instance over the past two years. That puts our customer rejection rate at a fraction of a percent.

Ask Your Suppliers for Context

Quality rating and on-time delivery are a great starting point for conversations with your supplier, but they shouldn’t be the conclusion. You should always try to understand what their quality rating actually measures, and how they approach potential quality or delivery issues in aerospace machining.

At Focused on Machining, we’re ready to talk about what’s behind the numbers. If you’re looking for contract manufacturing services, let’s discuss! Request a quote today!

A Service-Disabled Veteran-Owned Small Business for High-Volume Machining

Focused on Machining is a certified Service-Disabled Veteran-Owned Small Business (SDVOSB). Primes and OEMs can partner with us to fulfill supplier diversity and subcontracting goals at a shop that offers the production capacity and precision your programs require. 

Military Experience Shapes How We Operate

Our owner, Justin Quinn, served in the United States Air Force for six years as an aircraft mechanic and crew chief supporting C-17s. That environment demanded discipline that carries into our shop today.

Justin’s time working near jet engines ultimately led to cumulative hearing loss, which is the service-connected disability behind our SDVOSB status. When he became owner of Focused on Machining, he went through the U.S. Small Business Administration (SBA) to officially become a Service-Disabled Veteran-Owned Small Business. 

In recent years, that certification process has become more rigorous, requiring more records and supporting documentation. We’ve completed that review and can provide proof of certification when customers require it.

Helping You Meet Set-Aside Manufacturing Goals

Many government contracts require primes to meet subcontracting goals in categories like SDVOSB and woman-owned small businesses. As an SDVOSB, we help you satisfy goals in a simple way. By working with Focused on Machining, you can make substantial progress toward your targets.

A Small Business Built for Large Volumes

Don’t let the “small business” label mislead you. Primes can rely on Focused on Machining for high-volume production work and precision machining. Some primes think that sourcing sufficient volume for set-asides will require a large number of shops taking on small projects. At Focused on Machining, we have a proven history of multi-million dollar projects and multi-year orders.  

We’ve built our operation to support repeat production and long-term programs. You can simplify your set-aside process by sending more volume to a single qualified SDVOSB supplier.

Precision Capabilities for Demanding Programs

Set-aside eligibility only matters if a shop can meet the high standards of aerospace and defense manufacturing. We offer precision machining and are fully capable of handling tight tolerances, complex geometry, and difficult materials like Inconel. 

Our shop floor houses advanced equipment, including 5-axis capabilities. And our proven track record includes demanding programs for primes like ULA and Lockheed Martin.

Understanding Compliance Firsthand

One outcome of Justin’s military career is an understanding of the ins and outs of government work and systems. He has firsthand experience with the rules, regulations, and documentation processes that are central to federal requirements. He’s dealt with these systems for years, beginning in the military when they were part of his day-to-day operations in ordering parts for engines.

That familiarity extends into how we run our processes at Focused on Machining. Beyond SDVOSB, we’ve also navigated requirements like CMMC Level 2 compliance and AS9100D certification, so we’re prepared to support regulated programs with confidence.

An SDVOSB Ready for Your Toughest Projects

Primes are always impressed with our precision, but some may hesitate at first to send us projects for high-volume production machining services. They might think an SDVOSB partner may not have the capacity. But once we demonstrate our throughput and our responsiveness, those concerns disappear. Primes see they can have confidence in our shop.

Whether you need 5-axis machining or long-term contract manufacturing services, Focused on Machining is ready to help. Request a quote today from our Colorado machine shop, and let’s talk through your toughest parts.

On-Time Delivery Starts Early: Protecting Your Timelines With Scheduling Visibility

Some principles are just as important in both everyday life and manufacturing. One we’ve always followed at Focused on Machining is simple: don’t delay hard conversations. We’re proud of our 95% on-time delivery rate in our Colorado machine shop, but even in our shop, there are projects that might fall slightly behind plan. Waiting tends to only make outcomes worse, especially when lead times and schedules are on the line. 

If a project might be delayed, we have built our shop to have the visibility to know that weeks or even months in advance. We always reach out early, explain what we’re seeing, and work with you to decide the best path forward.

On-Time Delivery Is a Priority at FOM

On-time delivery is central to how we plan and manage our work every single day. As an AS9100 machine shop, our baseline internal target is 90% on-time delivery. However, we never settle for that goal; we consistently exceed that benchmark, and in many months are able to achieve 100%.

Still, manufacturing is complex, and the unexpected happens all the time. Processes shift, materials arrive late, or parts slip at an outside vendor. But helping you see the risk early can make the difference between costly delays and smooth adjustments.

In fact, one thing we’ve heard many times from prime contractors is that they’re surprised how far in advance we can identify a risk. For example, in a recent conversation with ULA, we reviewed parts that were due in four months. Based on our schedule visibility, we told them there was a risk of a slight delay. But they said the advance notice allowed them to evaluate their options and avoid any sort of last-minute scramble. It’s one part of our shop’s commitment to customer service.

Advanced Tech and Granular Planning Create Visibility

That level of visibility comes from planning our projects to an extremely granular level of detail. In ProShop ERP, we create schedules that account for every stage of our work, from planning and machining through inspection, outside processing, and shipping. For instance, we don’t just lump together every step of shipping into a vague task marked “ship”; instead, we schedule specific steps like reviewing shipping paperwork and wrapping parts for shipment.

At first, that level of detail can seem excessive to some people, but it’s truly critical to staying on track and keeping lead times accurate. For a high-volume job, final packaging and prep can take a full day. If you compress everything into a generic two-hour task, you’re setting yourself up for delays before the job even begins.

What We Do When a Schedule Is at Risk

If a task falls behind its planned date in ProShop, the system alerts us and highlights the projected impact on the final due date. We’ve always built in buffers due to the amount of uncertainty that is natural in manufacturing. But if we see that buffer disappearing, we know it's time to act.

Early visibility allows us to respond with intention. First, we confirm whether the schedule slip is minor enough for us to catch up on, or if it may affect delivery. If we think the risk is real, we alert you immediately to the possibility of late arrival. Then, we review available options together.

If the delay stems from our actions, we always own that and are prepared to implement internal expedites without changing the price. But if a vendor or outside process is the bottleneck, we’ll talk through expediting options and weigh the tradeoff between added cost and delivery. We always want to make sure you can make an informed choice about the best outcome for your project.

Choose a Proactive Manufacturing Partner

These situations are rare, but they do happen. And when they do, transparency is non-negotiable at Focused on Machining.

Trust is built through consistent performance and honest communication. As a machine shop that prides itself on on-time delivery, we treat your deadlines as our own, and back that up with planning and accountability.

If you need a precision machining partner for your next project, request a quote today!