IL CNC machining humidifier prototype process is a systematic workflow that transforms design concepts into physical prototypes, convalidare l'autenticità dell'aspetto, razionalità strutturale, water tightness, e logica funzionale fondamentale (PER ESEMPIO., mist output, silent operation). Questo articolo analizza il processo passo dopo passo, dalla progettazione preliminare al debug finale, utilizzando tabelle basate sui dati, indicazioni pratiche, e suggerimenti per la risoluzione dei problemi per aiutarti ad affrontare le sfide principali e garantire il successo del prototipo.
1. Preparazione preliminare: Gettare le basi per la lavorazione
Preliminary preparation defines the direction of the entire prototype development. Si concentra su due compiti fondamentali: 3D Modellazione & structural design E Selezione del materiale, both tailored to the unique needs of humidifiers (PER ESEMPIO., Resistenza all'acqua, mist uniformity, leggero).
1.1 3D Modellazione & Design strutturale
Use professional 3D modeling software to create a detailed prototype model, ensuring structural rationality and processability for CNC machining.
- Selezione del software: Prioritize tools like Solidworks, E nx, O Per/e—they support parametric design, allowing easy adjustment of key dimensions (PER ESEMPIO., water tank capacity, mist outlet size) and compatibility with CAM software for machining.
- Core Design Focus:
- Functional Requirement Alignment: Clarify key specs first—for household bedroom humidifiers, concentrarsi su silent design (fan noise ≤35dB) E soft lighting prompts; for industrial models, prioritize large humidification volume (≥500mL/h) e resistenza alla corrosione.
- Aspetto & 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 (misurare: typically 150×150×200mm).
- Internal Layout: Reserve space for critical components:
- Water tank (capacità: 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).
- Circuito (isolated from water-containing areas with a 5–8mm waterproof barrier).
- Key Detail Design:
- Spessore del guscio: 1-3 mm (plastica) or 2–4mm (metallo) 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).
Why is this important? A missing waterproof barrier between the circuit board and water tank can cause short circuits, richiedere 30% more rework time and increasing costs by 25%.
1.2 Selezione del materiale: Match Properties to Components
Different parts of the humidifier require materials with specific characteristics (PER ESEMPIO., water resistance for tanks, heat resistance for atomization chambers). The table below compares the most suitable options:
| Componente | Materiale | Proprietà chiave | Processing Requirements | Gamma di costi (al kg) |
| Shell (Household) | Plastica addominali | Basso costo, leggero, Facile da macchina | Spray matte paint (Ra1,6–Ra3,2); add anti-scratch coating | \(3- )6 |
| Shell (Industriale) | Lega di alluminio (6061) | Alta resistenza, Resistenza alla corrosione | Anodized (nero/argento); flatness error ≤0.02mm | \(6- )10 |
| Water Tank | Food-Grade PC/Stainless Steel (304) | Resistente all'acqua, non tossico, durevole | PC: Polished to transparency; 304: Finitura spazzolata (Ra0.8μm) | \(8- )12 |
| Atomization Chamber | PPS Plastic | Resistente al calore (fino a 200 ° C.), stabilità chimica | CNC machined with 0.1mm precision; no surface burrs | \(10- )15 |
| Sealing Rings/Gaskets | Gomma silicone | Impermeabile, resistente all'alta temperatura (-20°C–200°C) | Molded (no CNC); fits into tank/shell grooves with ±0.05mm tolerance | \(9- )13 |
Esempio: IL water tank uses food-grade PC for household humidifiers (transparency for water level checks) E 304 stainless steel for industrial models (corrosion resistance in harsh environments).
2. Processo di lavorazione CNC: From Setup to Component Production
The CNC machining phase is the core of prototype creation. It follows a linear workflow: process planning → machine & tool preparation → roughing & finishing → inspection & correction.
2.1 Process Planning
Define machining strategies to ensure efficiency and precision:
- Selezione degli strumenti:
| Materiale | Machining Task | Tipo di strumento | Specifiche |
| Plastica (ABS/PC) | Ruvido | Carbide Flat-End Mill | Φ6–Φ10mm, 2–3 teeth |
| Plastica (ABS/PC) | Finitura | Carbide Ball-Nose Mill | Φ2–Φ4mm, 4–6 teeth |
| Metallo (Aluminum/304) | Ruvido | High-Speed Steel End Mill | Φ8–Φ12mm, 2 denti |
| Metallo (Aluminum/304) | Finitura | Carbide End Mill | Φ3–Φ5mm, 4 denti |
- Parametri di taglio:
| Materiale | Stadio di lavorazione | Velocità (RPM) | Velocità di alimentazione (mm/dente) | Profondità di taglio (mm) | Refrigerante |
| Plastica addominali | Ruvido | 300–500 | 0.1–0,2 | 0.5–2 | Aria compressa |
| Plastica addominali | Finitura | 800–1200 | 0.05–0,1 | 0.1–0,3 | Aria compressa |
| Lega di alluminio | Ruvido | 800–1200 | 0.15–0,3 | 1–3 | Emulsione |
| Lega di alluminio | Finitura | 1500–2000 | 0.08–0,15 | 0.1–0,2 | Emulsione |
| 304 Acciaio inossidabile | Ruvido | 500–800 | 0.08–0,15 | 0.3–1 | Emulsione |
| 304 Acciaio inossidabile | Finitura | 1000–1500 | 0.03–0.08 | 0.05–0,1 | Emulsione |
- Machining Sequence:
- Ruvido: Remove 80–90% of blank allowance (PER ESEMPIO., shape the shell contour).
- Semifinishing: Reduce remaining allowance to 0.1–0.3mm (PER ESEMPIO., refine tank inner walls).
- Finitura: Achieve final dimensions and surface quality (PER ESEMPIO., polish mist outlets).
2.2 Macchina & Preparazione degli strumenti
- Machine Selection:
- Piccole parti (mist nozzles, pulsanti): Three-axis CNC milling machine (precisione di posizionamento ±0,01 mm).
- Grande parti (industrial tank shells): Four-axis machine (for curved surface machining).
- Configurazione degli strumenti:
- Install tools on the spindle and calibrate with a tool setter (precisione ±0,005 mm).
- Per parti di plastica, use sharp tools to avoid melting; per parti metalliche, check tool wear (replace if edge dullness exceeds 0.02mm).
2.3 Ruvido & Finishing Execution
- Roughing Tips:
- For thin-wall shells (1–2 mm), use low cutting force (reduce feed rate by 20%) per prevenire la deformazione.
- Per serbatoi d'acqua, machine the outer contour first, then the inner cavity to avoid material collapse.
- Finishing Focus:
- 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 Ispezione & Correzione
- Controlli dimensionali:
- Use calipers/micrometers to measure key specs (tank capacity ±5mL, shell thickness ±0.1mm).
- Usa una macchina di misurazione delle coordinate (CMM) per parti complesse (atomization chamber tolerance ±0.03mm).
- Ispezione superficiale:
- Controlla i graffi, pozzi, o irregolare (no visible defects on visible surfaces).
- Correction Measures:
- Dimensional deviation: Adjust tool compensation (PER ESEMPIO., 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. Post-elaborazione & Assemblaggio: Enhance Functionality & Estetica
Post-processing removes flaws and prepares components for assembly, while careful assembly ensures the prototype works as intended.
3.1 Post-elaborazione
- Sfacciato & Pulizia:
- Plastic Parts: Use a blade to remove burrs; clean with isopropyl alcohol to remove oil residue.
- Parti metalliche: Sand with 400–800 mesh sandpaper; per alluminio, anodize to form a 5–10μm protective film.
- Trattamento superficiale:
- Shell: Spray matte or glossy paint (polimerizzare a 60°C per 2 ore); silk-screen brand logos and operation labels.
- Water Tank (PC): Apply anti-fog coating to prevent mist condensation on inner walls.
- Metal Components: Electroplate (nickel or chrome) for corrosion resistance and aesthetics.
3.2 Assemblaggio & Debug
Follow a sequential order to avoid rework:
- Pre-Assembly Check: Verify all parts meet specs (PER ESEMPIO., 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).
- Shell & Functional Part Assembly:
- Snap or screw the shell together; attach mist outlets and buttons (test button feedback: 500–800g pressing force).
- Functional Debugging:
| 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, articolazioni, and connections. | No visible leakage from seams, articolazioni, 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, flat surface. 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 (PER ESEMPIO., fan, motore). Measure the noise level for 5 minuti, recording the average, massimo, and minimum values. | For household use, the average noise level should not exceed 35dB(UN) during normal operation, and the maximum peak noise should not exceed 40dB(UN). For industrial applications, the average noise level should be ≤50dB(UN), with a maximum peak noise of ≤55dB(UN). |
| Humidification Volume | Use the weight loss method to measure the humidification volume. Primo, 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. Dopo 1 ora, 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, Per esempio, 300ml/hour, the measured value should be between 285ml and 315ml per hour. |
4. Casi di applicazione: Tailor Processes to Use Scenarios
4.1 Household Small Humidifiers
- Messa a fuoco: Appearance personalization and user experience.
- Process Adjustments:
- Use ABS plastic for shells; test 2–3 color schemes (PER ESEMPIO., bianco, 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
- Messa a fuoco: Durability and performance under harsh conditions.
- Process Adjustments:
- Utilizzo 304 stainless steel for tanks; anodize aluminum shells for corrosion resistance.
- Precision-machine atomization nozzles (tolleranza ±0,03 mm) to ensure stable output in high-humidity (≥80% RH) ambienti.
- Prototype Value: Conduct 72-hour continuous operation tests; simulate dust and high temperatures (40° C.) to check component reliability.
La prospettiva della tecnologia Yigu
Alla tecnologia Yigu, Vediamo il CNC machining humidifier prototype process come a “risk reducer”—it identifies design flaws early to avoid mass production failures. Il nostro team dà priorità a due pilastri: precision and practicality. Per serbatoi d'acqua, we use food-grade materials and strict water-tightness testing (24-Immersione dell'ora) per garantire la sicurezza. For atomization chambers, we achieve ±0.03mm precision to guarantee uniform mist. Integriamo anche la scansione 3D post-lavorazione per verificare l'accuratezza dimensionale, riducendo i tassi di rilavorazione 25%. By tailoring processes to household or industrial needs, aiutiamo i clienti a ridurre il time-to-market di 1–2 settimane. Che tu abbia bisogno di un prototipo estetico o funzionale, we deliver solutions that align with user needs and industry standards.
Domande frequenti
- Q: How long does the entire CNC machining humidifier prototype process take?
UN: Normalmente 8-12 giorni lavorativi. This includes 1–2 days for design, 3–4 giorni per la lavorazione, 1–2 giorni per la post-elaborazione, 1–2 giorni per il montaggio, E 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?
UN: NO. Ordinary plastic (PER ESEMPIO., non-food-grade ABS) may leach chemicals into water, violating safety standards (PER ESEMPIO., FDA, Unione Europea 10/2011). Food-grade PC is non-toxic, resistente all'acqua, and durable—critical for parts in direct contact with water.
- Q: What causes uneven mist output, and how to fix it?
UN: Common causes are misaligned atomization devices (clearance >3mm from tank walls) or blocked mist outlets. Correzioni: Re-position the atomization device to ensure 2–3mm clearance; clean outlets with a 0.5mm needle to remove debris. This resolves 90% of mist uniformity issues in 1–2 hours.