Physical modelling continues to play a central role in automotive design development. Despite increasing digitisation, clay models allow evaluation of proportions, light reflection and surface validation in ways that screens still cannot reproduce with full fidelity. Automated milling of these models requires machines that are fast, accurate and adapted to the specific materials used in studios.
Context and challenge
LK Metrology, a British manufacturer of dimensional metrology equipment, has announced a new five-axis CNC milling solution aimed at producing physical models in clay, foam and hard board. The system is designed to meet the speed and surface-finish requirements of automotive design studios, where fast iteration between digital concept and physical validation continues to accelerate the development of new vehicles.
According to the manufacturer, the solution integrates a 4 kW spindle with rotation up to 25.000 rpm and operates at feed rates up to 40 m/min. The five-axis kinematics enable machining of complex surfaces and smooth transitions without manual repositioning, reducing total machining time and minimising tool marks.
The solution or technology
The technical configuration prioritises the structural rigidity required to maintain tight tolerances during removal of soft material, while providing sufficient dynamics to follow curved trajectories at high speed. The high-speed spindle allows use of smaller-diameter tools, suitable for the radii of curvature characteristic of automotive surfaces.
LK Metrology has its own subsidiaries across several continents, which, the company says, facilitates local technical support and supply of consumables. This aspect is relevant in continuous-production environments where unplanned stoppages affect critical development schedules.
Industrial applications
Clay milling is primarily intended for automotive design studios, where physical model makers transform CAD data into tactile prototypes. These models are used for aesthetic assessment, ergonomics testing, wind-tunnel aerodynamic flow analysis and validation of styling decisions before investment in tooling.
In addition to industrial clay, the solution processes polyurethane foam and hard board, materials used in interior mock-ups, instrument panels and centre consoles. The ability to switch between materials without extensive reconfiguration allows consolidation of multiple operations into a single work cell.
Results and benefits
High feed rates reduce cycle time in the production of large-scale models, freeing capacity for additional iterations or parallel projects. Five-axis kinematics improve surface finish by keeping the tool normal to the surface, reducing the need for subsequent manual polishing.
Availability of local support reduces mean time to repair and simplifies preventive maintenance planning. In environments where the machine operates continuously, predictable technical support contributes to workflow stability.
How NM3D can help
NM3D Ibérica represents the full LK Metrology portfolio in the Iberian Peninsula, including coordinate-measuring machines and complementary dimensional metrology solutions. Although clay milling is a distinct application, many design studios subsequently integrate portable metrology to validate the conformity of physical models against the original CAD data.
For projects that involve both physical prototyping and dimensional control, NM3D's technical team can assess complete workflows and propose configurations that cover production of the model through to its digitisation and three-dimensional inspection.
Related NM3D content: portable metrology for validation of physical models; 3D digitisation of prototypes.
Would you like to assess this solution for your application?
If your studio or development department is looking to integrate automated clay milling or needs to validate physical models with portable metrology, NM3D has the technical expertise and local support to assist the project from analysis through to continuous operation.