How parts become products.
Manufacturing processes transform raw material into components and assemblies. Choosing among machining, molding, casting, forming, fabrication, additive manufacturing, and other methods requires balancing geometry, material, tolerances, quantity, tooling, finish, and cost.
There is rarely one process that is best for every stage of production.
A prototype may be machined even when the production part will ultimately be molded or cast. A fabricated assembly may become a stamped component when volume increases. Process selection therefore requires looking at both the part itself and the production conditions surrounding it.
Explore manufacturing methods.
Each guide examines how the process works, where it fits into contract manufacturing, typical design considerations, and supplier capabilities that may affect sourcing.
CNC Machining
Computer-controlled milling and turning for precision components and production parts.
→ 02 / MOLDINGInjection Molding
Tool-based production of repeatable plastic components at medium and high volumes.
→ 03 / FABRICATIONSheet Metal Fabrication
Cutting, bending, forming, joining, and finishing sheet-based components.
→ 04 / FORMINGMetal Stamping
Press and die production for repeatable formed metal components.
→ 05 / CASTINGDie Casting
High-pressure metal casting for repeatable complex shapes and production volumes.
→ 06 / CASTINGInvestment Casting
Precision casting for detailed metal components and complex geometries.
→ 07 / FORMINGMetal Forging
Controlled deformation of metal to form strong production components.
→ 08 / CONTINUOUSExtrusion
Continuous-profile manufacturing for aluminum, plastics, rubber, and other materials.
→ 09 / ADDITIVEAdditive Manufacturing
Layer-based manufacturing for prototypes, tooling, fixtures, and selected production parts.
→ 10 / JOININGWelding
Joining processes used in fabricated components, frames, structures, and assemblies.
→ 11 / SECONDARYSurface Finishing
Processes used to modify appearance, corrosion resistance, wear, cleanliness, or texture.
→ 12 / QUALITYQuality Inspection
Measurement and verification methods used to confirm production requirements.
→Start with requirements, not equipment.
Geometry
Wall thickness, undercuts, cavities, features, size, complexity, and access influence process feasibility.
Material
Strength, heat resistance, corrosion behavior, machinability, formability, and melt characteristics matter.
Quantity
Production volume determines whether tooling investment can be justified and how automation affects cost.
Tolerance
Dimensional requirements can determine whether secondary machining or additional inspection is necessary.
Surface
Cosmetic appearance, roughness, coating, plating, cleaning, and corrosion protection may require secondary work.
Tooling
Dies, molds, fixtures, patterns, cutting tools, and gauges can affect both lead time and project economics.
Lead Time
Prototype urgency and production scheduling can make flexible processes more attractive early in a program.
Inspection
Measurement capability must be compatible with the tolerances and documentation required by the project.
The process may change as volume changes.
Early prototypes prioritize speed and design learning. Production processes must prioritize repeatability, cycle time, quality control, material utilization, tool life, labor, and total cost.
Manufacturing processes solve different production problems.
| Process | Tooling | Prototype Use | Production Volume | Typical Strength |
|---|---|---|---|---|
| CNC Machining | Low to moderate | Excellent | Low to medium | Precision and flexibility |
| Injection Molding | High | Limited without prototype tooling | Medium to high | Repeatable plastic parts |
| Metal Stamping | Moderate to high | Limited | Medium to very high | Fast repeatable formed parts |
| Die Casting | High | Limited | Medium to high | Complex metal geometry |
| Sheet Metal Fabrication | Low to moderate | Good | Low to medium | Flexible fabricated assemblies |
| Additive Manufacturing | Low | Excellent | Low / specialized production | Complex geometry and speed |
The process and the material have to work together.
Material properties affect machinability, moldability, formability, temperature performance, corrosion resistance, strength, and production cost.
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