Service
Simultaneous 5-Axis Milling
We machine complex 3D surfaces with a continuously changing angle between the tool and the workpiece. The synchronized movement of all five axes enables access to demanding areas and allows the tool position to adjust on the fly during cutting.
- Interpolated Axes
- 5 simultaneously
- Typical Surfaces
- 3D contoured
- Preparation
- CAM simulation
- File Formats
- STEP · IGES
Definition
What is simultaneous 5-axis milling?
Simultaneous 5-axis milling is a machining process where three linear axes (X, Y, Z) and two rotary axes move concurrently and in synchronization during cutting. This allows the tool's position and tilt relative to the workpiece to continuously adapt to the surface geometry.
Unlike 3+2 machining, where the rotary axes maintain a fixed position during cutting, simultaneous milling enables orientation changes on the fly within the same toolpath. This is particularly advantageous for complex contoured surfaces and areas that are difficult to access from a single fixed angle. By dynamically optimizing the tool tilt and path, cutting conditions and surface finish uniformity are significantly improved. The ability to use shorter cutting tools also increases system rigidity and minimizes vibrations during machining.
At Laika Tech, we perform simultaneous milling on aluminum, steel, stainless steel, brass, copper, and engineering plastics, catering to both single prototypes and batch production.
- Synchronized 5-axis motion with on-the-fly orientation changes during cutting
- Toolpath preparation and simulation in a CAM system
- Programming based on a 3D model, supplemented by a technical drawing for tolerances and specific requirements
How we execute simultaneous machining
| Interpolated Axes | 5 simultaneously (X, Y, Z + two rotary axes) |
|---|---|
| Operation Mode | Continuous simultaneous, utilizing 3+2 where more appropriate |
| Typical Surfaces | 3D contoured surfaces, drafts, undercuts, blend radii |
| Path Preparation | CAM with 5-axis module and collision simulation |
| In-Process Inspection | Touch probe measurement before part removal |
| Materials | Aluminum, steel, stainless steel, brass, copper, plastics |
| Production Volume | From single parts to batch production |
| File Formats | STEP or IGES — a 3D model is mandatory |
| Quote Turnaround | Within 48 hours of receiving the model |
| Location | Palinovec, Međimurje, Croatia |
The work envelope, maximum workpiece weight, and tolerances are detailed on the 5-Axis CNC Machining page.
Advantages
What you gain when the axes don't stop
In 3+2 machining, a curved surface is created through a series of separate orientations, each leaving a transition mark. Simultaneous milling glides over the same surface in one continuous motion — and you can see and feel the difference on the finished part.
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01
Surfaces without visible transitions
The tool traverses the entire curved surface in a single, uninterrupted pass, eliminating the lines where orientations would otherwise change.
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02
Better quality on contoured surfaces
By tilting the head, the tool cuts with its side rather than its tip. The engagement is wider and more uniform, requiring fewer passes and leaving less material for manual finishing.
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03
Shorter tools in deep cavities
Instead of a long tool plunging straight down, the head tilts and approaches from the side. A shorter tool vibrates less, maintains dimensional accuracy, and lasts longer.
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04
Undercuts without custom fixtures
Areas that are inaccessible from a locked position are reached through continuous motion, eliminating the need to manufacture dedicated workholding setups.
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05
Shorter cycle times on complex surfaces
There is no stopping, indexing, and re-entering the material between orientations. For 3D contoured surfaces, this constitutes the bulk of the time savings.
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06
Less manual post-processing
A uniform surface means less polishing and grinding — which, for molds and cosmetically critical parts, is often more expensive than the milling itself.
3+2 vs. simultaneous milling — what's the difference?
| Criterion | 3+2 Positional | Simultaneous 5-Axis |
|---|---|---|
| Motion during cutting | Three axes — rotary axes are locked | All five axes simultaneously |
| Continuously curved surface | Divided into a series of orientations | One uninterrupted pass |
| Finished surface appearance | Potential transition marks between positions | Uniform, without transition marks |
| Tool length | Often requires longer extension to reach the bottom | Shorter tool by tilting the head |
| CAM preparation | Simpler and faster | More demanding, requires collision simulation |
| Manufacturing documentation | A 2D drawing with dimensions is sufficient | A 3D model is required |
| When is it the right choice? | Flat surfaces and holes at various angles | 3D contoured surfaces and undercuts |
Simultaneous isn't automatically better — for a part with flat angled surfaces, 3+2 is faster, cheaper, and equally accurate. That's why we select the method that yields the required surface in less time for each part, and we frequently combine both on the same piece.
Applications
Parts requiring simultaneous machining
If a surface is continuously contoured, if the tool must reach undercuts, or if the finished surface is visible on the final product — this is the right process. For everything else, 3+2 indexing is typically the faster and more cost-effective choice.
Turbines, Impellers & Blades
Curved blades with varying angles that cannot be indexed into discrete planar orientations. The tool must trace the aerodynamic profile from root to tip in a single continuous pass.
Molds, Cores & Tooling
Mold cavities with organic contours, where any visible tool marks transfer directly to the end product and would require labor-intensive manual polishing.
Airfoils & Flow Profiles
Components where surface geometry governs fluid dynamics — guide vanes, diffusers, intakes. Step-over marks or orientation transitions alter aerodynamic function, not just cosmetic appearance.
Medical & Laboratory Components
Instruments and device components featuring smooth blend radii without sharp edges, where surface cleanliness and texture are just as critical as dimensional tolerance.
Parts with Undercuts & Angled Holes
Features that are simply unreachable from a fixed index position — the tool accesses them via continuous multi-axis motion, avoiding dedicated fixture design.
Complex Geometry Prototypes
One-off manufacturing directly from evolving 3D CAD models. Eliminates the tooling fabrication and dedicated setup time that would otherwise be discarded with each design revision.
Not sure if your part requires simultaneous machining? Send us your 3D model — we will evaluate whether it is manufacturable with 3+2 indexing or genuinely requires continuous multi-axis motion, and explain how that impacts pricing.
Send a 3D modelFrom the shop floor
Parts from our 5-axis center
A cross-section of what leaves our facility in Palinovec. Click on a photo to enlarge.
FAQ
Questions we frequently receive about simultaneous machining
In 3+2 machining, the workpiece is indexed into position, the rotary axes are locked, and cutting occurs along three axes. In simultaneous milling, all five axes move concurrently while the tool cuts, maintaining an optimal cutting angle relative to the surface at all times. As a result, curved surfaces are generated in a single continuous pass rather than through a series of discrete indexed orientations.
Simultaneous machining requires a 3D CAD model, typically in STEP or IGES format. The toolpath directly follows the true surface geometry, which cannot be reconstructed from a dimensioned 2D drawing alone. If you only have a 2D drawing, contact us and we can arrange the creation of the 3D model.
Toolpath preparation takes longer because it requires 5-axis CAM programming and collision simulation, making 3+2 the more cost-effective choice for simple parts. However, for contoured surfaces, simultaneous milling is often less expensive overall because it requires fewer passes and virtually eliminates manual benchwork after machining. Therefore, we price per component rather than strictly by the machining method.
We program toolpaths in CAM software equipped with a dedicated 5-axis module, based directly on your 3D model. Before the program is sent to the CNC machine, we run a full simulation to detect any collisions between the spindle head, cutting tool, and workholding fixtures. Only after passing simulation do we machine the first article.
For planar faces and hole features, 3+2 remains the most rigid and reliable method because cutting takes place from a locked position. The primary advantages of simultaneous machining lie in true 3D surface profiling and superior surface finish rather than individual linear tolerances. That is why we frequently combine both methods on the same part — machining each feature with the method best suited for it.
Yes, and that is our standard practice. Planar surfaces, holes, and threads are machined using 3+2 indexing for speed and rigidity, while contoured surfaces and undercuts are machined simultaneously. Everything is executed in the same setup, ensuring dimensional relationships between features remain perfectly preserved.
You don't need to determine this in advance. Simply send us your 3D model and specify the part's application — we will analyze the geometry and let you know whether it can be produced via 3+2 indexing or genuinely requires continuous multi-axis motion, along with the impact on pricing and lead time.
It depends on your surface finish specifications. Simultaneous milling delivers a consistent surface without transition marks between tool orientations, drastically reducing manual benchwork compared to 3+2 indexing. For mold cavities and cosmetic parts that demand a mirror finish, polishing is still required, but it starts from a vastly superior baseline.
Next Step
Send your model — we'll let you know how we would manufacture it.
We need your 3D model in STEP or IGES format, the specified material, and quantity. We will review the geometry, determine whether the part is manufacturable via 3+2 indexing or requires continuous multi-axis motion, and send a quote with lead time.
- STEP or IGES
- Quote within 48 hours
- Starting from 1 part