The "Sticker Shock" Problem
A high-quality Vertical Machining Center (VMC) costs ~$100,000. A comparable 5-Axis machine is ~$300,000. Most shop owners look at that $200k delta and walk away. They are missing the hidden cost: WIP (Work In Progress) and Labor.
The Cost of Multiple Setups
Consider a complex aerospace bracket.
- 3-Axis Process: Op1 (Top), Op2 (Side A), Op3 (Side B), Op4 (Side C), Op5 (fixture plate).
- 5-Axis Process: Op1 (Done-in-One), Op2 (Remove dovetail).
In 3-axis, that part sits on a shelf waiting for Op2, then Op3. It might take 2 weeks to ship. In 5-Axis, it ships the same day. Cash flow velocity is the killer app of 5-Axis.
ROI Calculation Example
Annual Savings (@$100/hr Shop Rate):
3.5 hrs savings × 12 runs = 42 hours = $4,200/yr per part number.
If you run 20 different jobs like this, that's $84,000/yr in pure setup savings.
Accuracy is Free
Every time you flip a part in a vise, you introduce stack-up error. A true 5-Axis machine holds spatial relationships perfectly. You aren't just paying for speed; you are paying to eliminate Scrap Rate caused by misloading Op4.
Verdict
If your typical part requires 3+ setups on a VMC, 5-Axis is not a luxury—it's likely cheaper per part than your current process.