Is Your Tapping Method Wasting Time and Money?
Tapping threads is a key step in manufacturing, but have you ever stopped to think about how much time and money your current method is actually costing you? We put three tapping methods to the test—CNC tapping, hand tapping, and tapping with a FlexArm—to find out which one gets the job done fastest and at the lowest cost.
The Test: 528 Tapped Holes
For this comparison, we tapped 16 holes per part—eight ½” -13 and eight ⅜”-16 across 33 parts. That adds up to 528 tapped holes. Let’s break down the time and cost of each method.
CNC Tapping: Effective but Expensive
Tapping with a CNC machine gets the job done, but at what cost? The full cycle time per part—including milling, drilling, and tapping, is 19 minutes and 23 seconds. The tapping portion alone takes 3 minutes and 24 seconds per part. When you factor in setup and changeover, tapping all 33 parts takes about 2.4 hours.
And here’s the kicker: with an average CNC operating cost of $100 per hour, you’re racking up expenses fast. Plus, every minute your CNC spends tapping is time it could be cutting the next part.
Hand Tapping: Slow and Painful
Hand tapping? Let’s just say it’s not for the faint of heart. In our test, taping just one hole by hand took 1 minute and 22 seconds. Multiply that by 528 holes, and you’re looking at over 12 hours of work. That’s a full shift and then some. Not to mention the physical strain on the operator leads to fatigue, inconsistency, and increased chances of error.
FlexArm Tapping: Fast, Easy, and Cost-Effective
Now let’s talk about the game-changer: the RE-16 Electric FlexArm. This powerhouse tapped the same part in just 1 minute and 50 seconds. Including changeover time, we finished all 33 parts in 1.18 hours, saving over an hour compared to CNC tapping.
But the real win? While your CNC is cutting the next part, the FlexArm is tapping the previous one. That means less downtime, greater throughput, and improved overall productivity.
Additional Benefits of Using a FlexArm
Beyond just speed and cost savings, using a FlexArm for tapping provides additional benefits:
- Improved Ergonomics: Hand tapping can be exhausting, leading to operator fatigue and potential injury. A FlexArm reduces strain, making tapping easier and more comfortable.
- Increased Accuracy: Human error is a big factor in hand tapping. A FlexArm provides consistent, high-quality threads every time.
- Versatility: With multiple models available, FlexArm can handle a variety of tap sizes and materials, making it a valuable asset for any shop.
- Reduced Machine Wear: Over time, frequent tapping on a CNC puts wear on the spindle and leads to more maintenance costs. Moving tapping to a FlexArm helps prolong the CNC machine’s life.
The Cost Breakdown: How Quickly Does a FlexArm Pay for Itself?
A FlexArm isn’t just faster—it saves money, too. Here’s how long it takes for each model to pay for itself based on labor savings:
- RE-16 Electric FlexArm: Job done in 1 hour and 10 minutes. Pays for itself in less than 12 days.
- A-32 Pneumatic FlexArm: Job done in 1 hour and 18 minutes. Lower upfront cost, perfect for job shops. Pays for itself in under 8 days.
- GH-30 Hydraulic FlexArm: Job done in 1 hour and 22 minutes. Slightly slower on small holes, but it is super versatile. Pays for itself in about 32 days.
The Bottom Line
CNC tapping takes 2.4 hours. Hand tapping? Forget about it. A FlexArm gets the job done in nearly half the time of CNC tapping, freeing up your machine for more important tasks.
For over 41 years, FlexArm has helped manufacturers save time and money with smarter tapping solutions. Want to see the difference yourself? Request a quote or give us a call at 937-210-9541 to speak to a FlexArm expert today!
