CNC & Precision Machining SWMS Templates

CNC and precision machining is not automatically high-risk construction work (HRCW) under WHS Regulation 2025 Schedule 3, which lists 19 specific construction activities. However, where machining occurs on a construction site or involves energised electrical work, hazardous chemicals, or confined spaces, HRCW triggers may apply. Even outside construction, the PCBU has a duty under WHS Reg Part 3.1 to document risk controls. A SWMS or equivalent safe operating procedure is industry best practice and is typically required by client and insurer audits.

A Safe Operating Procedure (SOP) is a step-by-step instruction for operating one specific machine, focused on correct use. A SWMS is a broader risk-based document covering the whole work activity — including hazards, controls, PPE, isolation, and emergency response — and is the format regulators expect for HRCW under WHS Regulation 2025. For CNC work, many shops use both: an SOP at the machine and a SWMS for setup, maintenance, or non-routine tasks involving multiple hazards.

Yes — while both are thermal cutting processes, the hazards differ significantly. Plasma cutting generates hexavalent chromium and metal fume requiring LEV per AS/NZS 1715 and produces UV and infrared radiation. Laser cutting introduces Class 4 laser hazards governed by AS/NZS IEC 60825.1, with specific eye protection, beam enclosure, and assist-gas requirements. Separate SWMS allow controls to be tailored: laser cutters need interlock verification and beam alignment procedures, while plasma tables need water table maintenance and downdraft testing.

Yes. Industrial additive manufacturing equipment — including FDM, SLA, SLS, and metal powder bed fusion printers — falls within the WHS Regulation 2025 definition of plant under Part 4.5. PCBUs must manage risks including hot surfaces, UV-curing radiation, resin skin sensitisation, and metal powder combustion. Powder-based systems require additional controls under AS/NZS 4745 for combustible dust. A SWMS should cover post-processing tasks such as resin washing, support removal, and powder recovery, which are often higher-risk than the print itself.

Retrofitted or imported second-hand CNC machines must still meet AS 4024.1-series safety of machinery requirements, regardless of original country of manufacture. Under WHS Regulation 2025 Part 4.5, the PCBU must ensure interlocked guards, emergency stops compliant with AS 4024.1604, and risk-assessed control systems. A pre-commissioning risk assessment is required. Older machines often need guarding upgrades, light curtains, or two-hand controls retrofitted before they can be safely operated. The SWMS should reference the commissioning risk assessment and verify isolation points.