5 Axis Machining vs 3 Axis: What You Need to Know

Intro to 5 Axis Machining

Why 3 and 4 Axis Shops Are Making the Move

As shops move past Q1 and reassess capacity, many are asking the same question. How do we reduce setups, increase spindle time, and keep more work in house without adding headcount?

For many 3 and 4 axis shops, the answer is not another machine. It is stepping into 5 axis.

And no, 5 axis is not just for aerospace or massive budgets anymore.

3 Axis vs 5 Axis: What Is the Real Difference?

A 3 axis machine moves in X, Y, and Z. To machine multiple sides of a part, you must stop, flip the part, re-indicate it, and run a new program. Every time the door opens, you lose time and risk alignment error.

A 5 axis platform adds two rotational axes. That means:

• You can machine multiple sides in one setup
• The part stays in the same datum
• You reach hard to access features without long tooling
• Surface finish remains consistent across features

In simple terms, less handling equals better accuracy.

What 5 Axis Looks Like in the Real World

Consider a typical multi face part.

On a 3 axis machine, it may require 6 or 7 operations. Each setup requires indicating, touching off, and verifying location. 

On a 5 axis machine, that same part can often be completed in 2 operations. That is up to a 70 percent reduction in setups.

When you reduce setups, you reduce:

• Operator handling
• Re indicating and probing
• Tool changes across multiple machines
• The chance for misalignment

Setup time must be counted as real production time. Every time the door is open, the spindle is not cutting. 5 axis is not just about cutting faster. It is about eliminating non cutting time.

The Hidden Cost Savings Most Shops Miss

Moving from 3 axis to 5 axis affects more than cycle time.

Labor savings

Fewer changeovers reduce operator involvement and free up labor for other tasks.

Scrap and rework reduction

Fewer setups mean fewer opportunities for misalignment and tolerance stack up.

Tool wear savings

Shorter tools improve rigidity and extend tool life. You no longer rely on excessive stick out to reach difficult features. 

One program instead of several

When a part changes, you update one program instead of rewriting multiple programs for multiple setups. Troubleshooting becomes simpler.

Even Simple Parts Benefit

One common misconception is that 5 axis is only for highly complex geometry.

In reality, many shops begin with a 3 plus 2 approach. You index the part to machine multiple sides in fewer setups, even if you are not running full simultaneous motion.

For example: 

3 Axis:

3 setups x 20 minutes = 60 minutes non cut time

• • 40 minutes cut time = 100 minutes per part

5 Axis:

1 setup x 20 minutes = 20 minutes non cut time

• • 30 minutes cut time = 50 minutes per part

That difference scales quickly over hundreds or thousands of parts per year.

This is not about exotic parts. It is about eliminating wasted time.

Lowering the Barrier to Entry

Programming complexity is often a concern.

If your team understands 3 axis machining, stepping into 3 plus 2 is a manageable next step. Modern controls simplify programming, probing, simulation, and machine compensation.

The Okuma OSP ecosystem integrates the machine, tool changer, and pallet functions into one control environment. That reduces the complexity that often comes with multi vendor integration.

Built in probing and simulation tools help reduce risk during prove out. Machine compensation features maintain long term accuracy and thermal stability.

Combined with Morris applications support, training, and full workflow consulting, shops are not left to figure it out alone.

Where 5 Axis Adds Immediate Value

5 axis machining delivers value by:

• Handling complex or multi face parts
• Reducing setups
• Improving surface finish
• Holding tighter tolerances
• Consolidating operations
• Increasing spindle utilization
• Saving floor space by replacing multiple machines

Machines like the GENOS M460V-5AX and MU-4000V offer high accuracy, compact footprints, and automation ready platforms for small and mid size manufacturers. 

For shops looking to scale without expanding headcount, that matters.

Is Your Shop a 5 Axis Candidate?

You likely are if you:

• Run low volume, high mix parts
• Flip parts multiple times per job
• Struggle with tolerance stack ups
• Use long tools to reach features
• Spend more time setting up than cutting

It is rare for a modern machine shop not to benefit from 5 axis capabilities. 

The real question is not whether 5 axis fits, but how much time you are currently losing without it?

See What 5 Axis Could Change in Your Shop
Bring us a current part print. We will review your setup strategy and show you where 5 axis can reduce time and risk.