What are the most challenging design features you’ve encountered when working with CNC machining, and how did you overcome them?

CNC machining is a powerful tool for producing highly precise and complex components, but certain design features can pose significant challenges. From intricate geometries and tight tolerances to material constraints and machining limitations, these hurdles test the limits of both designers and manufacturers.
I’d love to hear about the most difficult design features you’ve faced in your CNC machining projects. How did you approach these challenges? Did you modify the design, adjust machining parameters, or use innovative techniques to overcome them?
Let’s share insights and solutions to help the community tackle these challenges more effectively!
Accepted answer

Extreme aspect ratios (feature to tool diameter), minimum radii etc., and understanding capabilities; machine and tooling. 5-axis can alleviate some of these issues in some cases. But, still probably some of the more difficult challenges in that world. Same can be said for thin walls in high-strength materials, which are typical of titanium aero components.
1 Other answer

One of the biggest challenges I've faced with CNC machining is dealing with complex geometries, especially undercuts and deep cavities. To overcome this, I often use smaller tools for detail work and adjust cutting parameters for optimal precision. Multiple setups can also help achieve the best results without compromising on tolerance. Always a balance between design and machine capabilities!