Manufacturing Processes

Why CNC Machining Beats Traditional Machining Every Time

The advent of computers brought the concept of numerical systems to reality for many industries. Manufacturing, in particular, has widely embraced the technology, with CNC machining now seen as the gold standard and offering many advantages over more traditional measures. CNC vs. Traditional Machining: the basics CNC stands for Computer Numerical Control and such a …

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The revolutionary metal 3D printer developed at TU Graz

Revolutionary New Metal 3D Printing Technology (Selective LED-based Melting)

Metal 3D printing can also be known as DMLS (Direct Metal Laser Sintering), and DMLM (Direct Metal Laser Melting) is an additive layer technology. A metal 3D printer uses a laser beam to melt 20-60 micron layers of metal powder on top of one another. This powdered metal is spread out over the entire build …

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CNC Fabrication: 3, 4 and 5-Axis CNC Explained

CNC Fabrication: 3, 4 and 5-Axis CNC Explained

CNC fabrication involves the use of Computer Numerical Control (CNC) machines to shape and resize a block of material (known as a workpiece) by automatically removing bits of the material. Typically, the materials used are plastic or metal, and when the removal is completed a finished part or product has been produced. This process is …

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What is Parylene coating and when should you use it?

Deciding on the ideal coating for your engineering application is always a very difficult task, you need to decide on chemical, process, mechanical and component compatibility. Some coatings are not ideal for specific applications. There are many different types of coatings for a vast array of applications, however this post will focus on an advanced …

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HALT testing

HALT Testing (Highly Accelerated Life Testing)

Highly Accelerated Life Testing (HALT) refers to a reliability testing technique that aims to expose the weaknesses of a product. The main objective is to expose the product to incremental stresses, in order to discover flaws and defects. A HALT test must be conducted during the early stages of the product design process. HALT was …

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Electroforming

What is Electroforming and where is it used?

The best way to describe electroforming is a metal forming process used to manufacture parts using electrolyte deposition onto a model. In the manufacturing industry this model is known as a mandrel. It is a highly specialized process which sounds fairly simple in theory but not so easy in practice. We will now take a …

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shot blasting machine

A Guide to Shot Blasting / Shot Peening

Shot peening (also known as shot blasting) is a surface conditioning process carried out after various manufacturing processes. In simple terms it increases/improves the surface finish. Shot peening is done with the help of small balls which are streamed out in the form of a jet at very high velocity, accelerated and directed toward a …

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US Marine Corps special operations command Marsoc raider with parkerized gun

What is Parkerizing, how does it work?

Parkerizing is a method used on ferrous metals such as wrought iron, cast iron, steel and alloy steel, offering added protection from corrosion. This process is not suitable for non-ferrous metals like a copper, brass, aluminium, and plastic items. It can also be used to improve the wear resistance of materials by adding a surface …

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electropolished engine

What is Electropolishing and what is it used for?

Electropolishing is a material removal process using an electrically powered chemical process called electrolysis. In this process the amount of material being removed is very small as it is done for polishing purposes only. A negatively charged copper electrode and positively charged workpiece are dipped into a solution of fast flowing electrolyte solution. When connected …

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Circular sawing – process description and design guide

Circular sawing involves the use of a rotating cutting blade that can be fed horizontally, vertically, or at an angle into the material. Circular sawing is highly accurate because of the rigidity of the machines and the cutting blade. This process can produce burr-free surfaces and can reduce the need for secondary finishing operations. The …

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EDM Machines

EDM Machine – types & working principles

EDM stands for Electrical Discharge Machining. An EDM machine is the piece of equipment used to carry out this manufacturing process. The principle behind EDM was first observed in 1770 by Joseph Priestley, who was experimenting with electrical discharges. He noticed that the sparks had eroded some of the electrode material. Almost 200 years later …

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compression molding - car tyres

Compression Molding – manufacturing process guide

Compression molding is one of the oldest and most widely used processes for the production of thermosetting plastic parts. Compression molding machines consist of platens to which the two halves of a mold is attached. The name given to the raw material used for the production of the parts is known as a charge. A calculated …

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Rifling - broaching

Linear Broaching & Rotary Broaching: Process Guide

What is Broaching? How does a broach work? Broaching is a subtractive manufacturing process that produces features by removing material form a part with a toothed tool known as a broach. The process is divided into two main types: linear broaching and rotary broaching. Both variants are detailed in the article below. This process is …

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Electron Beam Melting (EBM)

Electron Beam Melting (EBM): process, materials, uses

Many types of additive layer manufacturing processes have become well-known in recent years, but Electron Beam Melting (EBM) is still relatively new an uncommon. Electron Beam Melting does not require molds to be produced and is therefore a less expensive and faster lead-time manufacturing process than many traditional processes like casting, forging, and machining. It …

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Pressure Die Casting PDC process diagram

Die Casting – design guide, materials, advantages and disadvantages

Die casting is a permanent mould casting process in which molten metal is poured into a mould and removed after solidification. There are two main types of this process: Gravity Die Casting (GDC) and Pressure Die Casting (PDC). In GDC, molten metal is poured into the mould using gravity. In PDC, the molten metal in …

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What is the best ERP software for plastic injection moulding products?

Injection moulding seems like it would be a straightforward process. Simply insert the plastic pellets into the hopper, inject the molten material into a mould, pop it out and repeat – not much planning or organising involved. That is until you start doing it on a large scale. This is where ERP software becomes imperative …

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CNC prototyping

CNC prototyping: 5 things you need to know

Computer Aided Design (CAD) was seen by many as a turning point in the world of business but now we have Computerised Numerical Control (CNC). The ability to directly convert a 3D CAD file into an actual prototype component brings with it an array of significant benefits. There is no doubt that CNC is rebasing …

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steel mill cobble

Extreme manufacturing danger: the steel mill cobble

While many of us will be well aware of the dangers of working in a steel mill, the excessive temperatures and molten steel, few people will have heard of the steel mill cobble. Unfortunately for those working in these challenging and dangerous environments the term “steel mill cobble” does not really reflect the dangers associated …

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5 Absolutely Mental Manufacturing Processes

What you’re about to witness is a roundup of some absolutely mental manufacturing techniques that are insanely interesting, and just a little bit wacky. Some will make you awe-struck at their ingenuity, some will make you question everything you know, and at least one will make you ask ‘what’s the point?’ Well, the point is …

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Additive Manufacturing in the Aerospace Industry

You know a trend transitioned from a hobbyist tool and news candy to solid production asset when aeronautics and aerospace officially start using it. Additive manufacturing (also referred to as 3D Printing) crossed that milestone some time ago for several industries. The aero field is now making additive manufacturing the way of tomorrow and as …

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advantages of injection moulding

What are the main advantages of injection moulding over traditional manufacturing?

To the untrained eye it may be easy to assume that injection moulding is simply a quicker and more cost-effective method of manufacturing when compared to traditional methods. While this is obviously a major attraction for those looking at injection moulding there is much more to this process than just speed and cost. We will …

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automation basics - an automated production line

Automation Basics – An Introduction

Automation basics: The term automation is derived from the Greek root words of ‘Auto’, meaning “self”, and ‘Matos’, meaning “moving”. So, automation can be described as a mechanism that has the ability to move by itself. Automated systems tend to achieve significantly superior performance to manual systems, specifically in terms of power, precision and speed. …

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tooling design

A Basic Guide to Tooling Design

The discipline of tooling design is fundamental to manufacturing. The cost of manufacturing and of the end product depends heavily upon tool design. Tool design affects cost in several ways. First, it determines the tool life, which is how long the tool last before requiring a replacement. Second, it affects the quality of the product, and …

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