El CNC machining humidifier prototype process Es un flujo de trabajo sistemático que transforma conceptos de diseño en prototipos físicos., validar la autenticidad de la apariencia, structural rationality, water tightness, y lógica funcional central (P.EJ., mist output, silent operation). Este artículo desglosa el proceso paso a paso, desde el diseño preliminar hasta la depuración final, utilizando tablas basadas en datos., directrices prácticas, y consejos para la resolución de problemas que le ayudarán a afrontar los desafíos clave y garantizar el éxito del prototipo..
1. Preparación preliminar: Sentar las bases para el mecanizado
La preparación preliminar define la dirección de todo el desarrollo del prototipo.. Se centra en dos tareas centrales.: 3D Modelado & diseño estructural y selección de material, both tailored to the unique needs of humidifiers (P.EJ., resistencia al agua, mist uniformity, ligero).
1.1 3D Modelado & Diseño estructural
Utilice un software de modelado 3D profesional para crear un modelo prototipo detallado, Garantizar la racionalidad estructural y la procesabilidad para el mecanizado CNC..
- Selección de software: Priorizar herramientas como Solidworks, Y nx, o Delantero—apoyan el diseño paramétrico, permitiendo un fácil ajuste de las dimensiones clave (P.EJ., water tank capacity, mist outlet size) y compatibilidad con software CAM para mecanizado.
- Enfoque de diseño central:
- Functional Requirement Alignment: Clarify key specs first—for household bedroom humidifiers, concentrarse en silent design (fan noise ≤35dB) y soft lighting prompts; for industrial models, prioritize large humidification volume (≥500mL/h) y resistencia a la corrosión.
- Apariencia & Internal Structure Integration:
- Shell Shape: Adopt rounded lines (radius 5–8mm) for household models to fit home decor; use compact geometric shapes for desktop versions (tamaño: typically 150×150×200mm).
- Internal Layout: Reserve space for critical components:
- Water tank (capacidad: 1–3L for household, 5–10L for industrial).
- Atomization device (ultrasonic or thermal, with 2–3mm clearance from tank walls).
- Fan (positioned to avoid mist backflow).
- Tarjeta de circuitos (isolated from water-containing areas with a 5–8mm waterproof barrier).
- Diseño de detalles clave:
- Espesor de la cáscara: 1-3 mm (plástico) or 2–4mm (metal) to balance strength and weight.
- Assembly Structures: Add buckles (for shell connection) and M2–M3 screw holes (for fixed components) with ±0.1mm tolerance.
- Functional Features: Design mist outlets (diameter 8–12mm, 2–4 holes for uniform spray) and vents (grid pattern, hole size 2–3mm for dust prevention).
¿Por qué es esto importante?? A missing waterproof barrier between the circuit board and water tank can cause short circuits, requerido 30% more rework time and increasing costs by 25%.
1.2 Selección de material: Hacer coincidir propiedades con componentes
Different parts of the humidifier require materials with specific characteristics (P.EJ., water resistance for tanks, heat resistance for atomization chambers). The table below compares the most suitable options:
| Componente | Material | Propiedades clave | Processing Requirements | Rango de costos (por kg) |
| Caparazón (Household) | De plástico de los abdominales | Bajo costo, ligero, fácil de mecanizar | Pintura mate en aerosol (Ra1.6–Ra3.2); add anti-scratch coating | \(3- )6 |
| Caparazón (Industrial) | Aleación de aluminio (6061) | Alta fuerza, resistencia a la corrosión | Anodized (negro/plata); flatness error ≤0.02mm | \(6- )10 |
| Water Tank | Food-Grade PC/Stainless Steel (304) | Resistente al agua, no tóxico, durable | ordenador personal: Polished to transparency; 304: Acabado cepillado (Ra0.8μm) | \(8- )12 |
| Atomization Chamber | PPS Plastic | A prueba de calor (hasta 200 ° C), estabilidad química | CNC machined with 0.1mm precision; no surface burrs | \(10- )15 |
| Sealing Rings/Gaskets | Goma de silicona | Impermeable, resistente a la alta temperatura (-20°C–200°C) | Molded (no CNC); fits into tank/shell grooves with ±0.05mm tolerance | \(9- )13 |
Ejemplo: El water tank uses food-grade PC for household humidifiers (transparency for water level checks) y 304 stainless steel for industrial models (corrosion resistance in harsh environments).
2. Proceso de mecanizado CNC: De la configuración a la producción de componentes
La fase de mecanizado CNC es el núcleo de la creación de prototipos.. Sigue un flujo de trabajo lineal.: process planning → machine & tool preparation → roughing & finishing → inspection & corrección.
2.1 Process Planning
Define machining strategies to ensure efficiency and precision:
- Selección de herramientas:
| Material | Tarea de mecanizado | Tipo de herramienta | Presupuesto |
| Plástico (ABS/PC) | Toscante | Carbide Flat-End Mill | Φ6–Φ10mm, 2–3 dientes |
| Plástico (ABS/PC) | Refinamiento | Molino de punta esférica de carburo | Φ2 - φ4MM, 4–6 dientes |
| Metal (Aluminum/304) | Toscante | Fresa de acero de alta velocidad | Φ8–Φ12mm, 2 dientes |
| Metal (Aluminum/304) | Refinamiento | Fresa de carburo | Φ3–Φ5mm, 4 dientes |
- Parámetros de corte:
| Material | Etapa de mecanizado | Velocidad (rpm) | Tasa de alimentación (mm/diente) | Profundidad de corte (milímetros) | Refrigerante |
| De plástico de los abdominales | Toscante | 300–500 | 0.1–0,2 | 0.5–2 | Aire comprimido |
| De plástico de los abdominales | Refinamiento | 800–1200 | 0.05–0,1 | 0.1–0,3 | Aire comprimido |
| Aleación de aluminio | Toscante | 800–1200 | 0.15–0,3 | 1–3 | Emulsión |
| Aleación de aluminio | Refinamiento | 1500–2000 | 0.08–0,15 | 0.1–0,2 | Emulsión |
| 304 Acero inoxidable | Toscante | 500–800 | 0.08–0,15 | 0.3–1 | Emulsión |
| 304 Acero inoxidable | Refinamiento | 1000–1500 | 0.03–0,08 | 0.05–0,1 | Emulsión |
- Machining Sequence:
- Toscante: Eliminar entre el 80% y el 90% de la asignación en blanco (P.EJ., shape the shell contour).
- Semifinisco: Reduce remaining allowance to 0.1–0.3mm (P.EJ., refine tank inner walls).
- Refinamiento: Achieve final dimensions and surface quality (P.EJ., polish mist outlets).
2.2 Máquina & Preparación de herramientas
- Machine Selection:
- Piezas pequeñas (mist nozzles, botones): Three-axis CNC milling machine (precisión de posicionamiento ±0,01 mm).
- Grandes partes (industrial tank shells): Four-axis machine (for curved surface machining).
- Configuración de herramientas:
- Install tools on the spindle and calibrate with a tool setter (accuracy ±0.005mm).
- Para piezas de plástico, use sharp tools to avoid melting; para piezas de metal, check tool wear (replace if edge dullness exceeds 0.02mm).
2.3 Toscante & Finishing Execution
- Roughing Tips:
- For thin-wall shells (1–2 mm), use low cutting force (reduce feed rate by 20%) para evitar la deformación.
- For water tanks, machine the outer contour first, then the inner cavity to avoid material collapse.
- Enfoque final:
- Ensure mist outlets are burr-free (use 800–1200 mesh sandpaper for manual polishing).
- For transparent PC tanks, achieve surface roughness Ra ≤0.8μm to avoid mist adhesion.
2.4 Inspección & Corrección
- Controles dimensionales:
- Use calipers/micrometers to measure key specs (tank capacity ±5mL, shell thickness ±0.1mm).
- Use una máquina de medición de coordenadas (Cmm) para piezas complejas (atomization chamber tolerance ±0.03mm).
- Inspección de la superficie:
- Verifique los rasguños, pozos, o desigualidad (no visible defects on visible surfaces).
- Correction Measures:
- Dimensional deviation: Adjust tool compensation (P.EJ., increase cutting depth by 0.05mm if the shell is too thick).
- Poor surface quality: Reduce feed rate by 10–15% and re-finish.
3. Postprocesamiento & Asamblea: Mejorar la funcionalidad & Estética
El posprocesamiento elimina defectos y prepara los componentes para el montaje., while careful assembly ensures the prototype works as intended.
3.1 Postprocesamiento
- Desacuerdo & Limpieza:
- Piezas de plástico: Utilice una cuchilla para eliminar las rebabas.; clean with isopropyl alcohol to remove oil residue.
- Piezas de metal: Lije con papel de lija de malla 400–800; para aluminio, anodize to form a 5–10μm protective film.
- Tratamiento superficial:
- Caparazón: Spray matte or glossy paint (cure at 60°C for 2 horas); silk-screen brand logos and operation labels.
- Water Tank (ordenador personal): Apply anti-fog coating to prevent mist condensation on inner walls.
- Metal Components: Electroplate (nickel or chrome) for corrosion resistance and aesthetics.
3.2 Asamblea & Depuración
Follow a sequential order to avoid rework:
- Comprobación previa al montaje: Verify all parts meet specs (P.EJ., sealing ring size matches tank grooves).
- Core Component Installation:
- Fix the atomization device to the tank base (use silicone gaskets for water tightness).
- Install the fan and circuit board (ensure 5–8mm waterproof gap from water areas).
- Caparazón & Functional Part Assembly:
- Snap or screw the shell together; attach mist outlets and buttons (test button feedback: 500–800g pressing force).
- Depuración funcional:
| Test Item | Tools/Methods | Pass Criteria |
| Water Tightness | Fill the water tank to 80% of its total capacity, ensuring that the level is consistent across all sides. Place the humidifier in its upright, operational position and let it stand undisturbed for 24 hours in a controlled environment with stable temperature and humidity levels. Check for any signs of moisture accumulation or dripping around the seams, articulaciones, and connections. | No visible leakage from seams, articulaciones, or connections; no moisture pooling on surfaces in contact with the humidifier. The water level should not drop by more than 1% due to evaporation during the testing period. |
| Mist Uniformity | Position a precision mist collector at a fixed distance of 10cm directly in front of the mist outlet. Use a high-precision flow meter to measure the mist output at multiple points within a 5cm radius of the center of the mist stream. Conduct measurements at 5-second intervals for a total duration of 3 minutes. | The variation in mist output across all measured points should not exceed 10% of the average output value. There should be no visible droplets of water falling from the mist stream, indicating a fine, consistent mist. |
| Noise Level | Place the humidifier on a stable, superficie plana. Position a calibrated Class 1 sound level meter at a distance of 1m from the center of the humidifier, at the same height as the main components that generate noise (P.EJ., fan, motor). Measure the noise level for 5 minutos, recording the average, máximo, and minimum values. | For household use, the average noise level should not exceed 35dB(A) during normal operation, and the maximum peak noise should not exceed 40dB(A). For industrial applications, the average noise level should be ≤50dB(A), with a maximum peak noise of ≤55dB(A). |
| Humidification Volume | Use the weight loss method to measure the humidification volume. Primero, weigh the humidifier with a full water tank using a high-precision scale. Start the humidifier and let it run continuously for 1 hour under normal operating conditions. Después 1 hora, stop the humidifier and immediately weigh it again. Calculate the weight loss, which corresponds to the volume of water converted into mist. | The measured weight loss should meet the design specifications within a tolerance of ±5%. If the design specifies a humidification volume of, Por ejemplo, 300ml/hour, the measured value should be between 285ml and 315ml per hour. |
4. Casos de aplicación: Tailor Processes to Use Scenarios
4.1 Household Small Humidifiers
- Enfocar: Appearance personalization and user experience.
- Process Adjustments:
- Use ABS plastic for shells; test 2–3 color schemes (P.EJ., blanco, light gray) via spray painting.
- Optimize button layout (1–2 buttons for on/off and mist level) and test ergonomics (easy to press with one hand).
- Prototype Value: Verify if the design fits nightstands (size ≤150×150mm) and if the silent fan avoids disturbing sleep.
4.2 Industrial Large Humidifiers
- Enfocar: Durability and performance under harsh conditions.
- Process Adjustments:
- Usar 304 stainless steel for tanks; anodize aluminum shells for corrosion resistance.
- Precision-machine atomization nozzles (tolerance ±0.03mm) to ensure stable output in high-humidity (≥80% RH) entornos.
- Prototype Value: Conduct 72-hour continuous operation tests; simulate dust and high temperatures (40° C) to check component reliability.
La perspectiva de la tecnología de Yigu
En la tecnología yigu, Vemos el CNC machining humidifier prototype process como “risk reducer”—it identifies design flaws early to avoid mass production failures. Our team prioritizes two pillars: precision and practicality. For water tanks, we use food-grade materials and strict water-tightness testing (24-inmersión de la hora) Para garantizar la seguridad. For atomization chambers, we achieve ±0.03mm precision to guarantee uniform mist. También integramos el posmecanizado de escaneo 3D para verificar la precisión dimensional., reducir las tasas de retrabajo 25%. By tailoring processes to household or industrial needs, Ayudamos a los clientes a reducir el tiempo de comercialización entre 1 y 2 semanas.. Ya sea que necesite una apariencia o un prototipo funcional, we deliver solutions that align with user needs and industry standards.
Preguntas frecuentes
- q: How long does the entire CNC machining humidifier prototype process take?
A: Typically 8–12 working days. This includes 1–2 days for design, 3–4 days for machining, 1–2 días para el posprocesamiento, 1–2 days for assembly, y 1 day for debugging. Industrial models may take 2–3 extra days due to larger size and stricter testing.
- q: Can I use ordinary plastic instead of food-grade PC for the water tank?
A: No. Ordinary plastic (P.EJ., non-food-grade ABS) may leach chemicals into water, violating safety standards (P.EJ., FDA, UE 10/2011). Food-grade PC is non-toxic, resistente al agua, and durable—critical for parts in direct contact with water.
- q: What causes uneven mist output, y como solucionarlo?
A: Common causes are misaligned atomization devices (clearance >3mm from tank walls) or blocked mist outlets. Corrección: Re-position the atomization device to ensure 2–3mm clearance; clean outlets with a 0.5mm needle to remove debris. Esto resuelve 90% of mist uniformity issues in 1–2 hours.