Category Archives: Process

Injection Molding Aluminum

Injection molding is a manufacturing process where a material is injected into a mold to create a desired shape. Typically, this process is used for plastics, but it is also possible to use it for metals like aluminum. Aluminum injection molding involves melting aluminum pellets and injecting them into a mold cavity under high pressure. The aluminum solidifies quickly in the mold, taking the shape of the cavity. Once the aluminum has cooled and hardened, the mold is opened, and […]

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Comparing Metal Parts Manufacturing Methods

From machining to MIM, metal parts buyers have a wide range of options for addressing their part-production challenges. The key in choosing from among them is to remember that each technology brings something different to the table, and every part has unique requirements. Metal fabrication does not lack for depth as an industry. No fewer than 6 distinct — and commonly used — techniques exist for the manufacture of metal pieces and parts in 2019. Each can be considered the […]

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Common manufacturing processes for plastic and metal parts

One important tenet of Design for Manufacturing / Design for Assembly is the idea that the mechanical engineer and the industrial designer should choose the manufacturing processes that will be used to mass produce custom parts before finalizing the design for that part (and everything that it touches). Here are some common processes that are used to produce plastic and metal parts in consumer electronics and industrial automation applications. Some post-processes for plastic parts Sometimes plastic parts have to go […]

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Finishing Operations for Forgings

There are two categories of finishing operations: those that produce minor dimensional corrections, and surface treatment processes. Coining, sizing and straightening are commonly used to improve the dimensional accuracy of forgings. When tolerances closer than those that can be economically produced in the forging die are specified, coining and sizing operations are often employed. These processes cause plastic deformation of the forging, either by striking or squeezing a defined area. Coining may be performed either hot or cold, and can […]

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Warm Forging Process

Warm forging is performed with the workpiece heated to a range that is generally above the work hardening temperature and below the temperature at which scale forms. The process fills the niche between the closer tolerance, but sometimes expensive cold forging process and the somewhat lower precision hot forging process. It is being used to produce close tolerance components in steel alloys that were not feasible or impossible by cold forging. It is also being used to produce components very […]

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Cold Forging Process

Cold Forging Process Cold forging is one of the most widely used chipless forming processes, often requiring no machining other than drilling. The commonly accepted definition is the forming or forging of a bulk material at room temperature with no heating of the initial slug or inter-stages. The term “no heating” does not include in-process annealing, which may be performed at intermediate stages to relieve the effects of work hardening. The process produces greater dimensional accuracy than hot forming, and […]

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The process of injection molding explained

Injection molding is a manufacturing process used to produce single parts and products using various materials, most commonly thermosetting and thermoplastic polymers. Today, injection molding is the most popular method of manufacturing parts and is used to produce a variety of everyday plastic products, including packaging, toys, telephones, bottle lids, chairs and many more. Injection molding is also used to manufacture complex, small metal parts, known as Metal Injection Molding (MIM). But just how does injection molding work? The machine An injection […]

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3D Printing is Changing Manufacturing of Complex Composite Parts

3D printing is an additive manufacturing process that works best for functional prototypes, complex designs, reducing multipart assemblies, and end-use applications. 3D printing technology is rapidly changing how manufacturers are creating concept models and end-use parts. One of the fastest growing applications is utilizing 3D printing technology for the tooling of complex and low volume composite parts. Boeing and other companies in the aerospace and automotive industries are finding that using composite materials instead of metal, greatly reduces the weight and […]

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Top-10 Injection Molding Defects and How to Fix Them

Making injection molded prototypes is both an art and a science. High levels of technical expertise and attention to detail are required to prevent small mistakes from costing companies big money when it comes to mass-production of novel parts. Preventing such a circumstance is all about highly competent design. This article discusses some of the molding defects that can occur in a part during injection molding, and ways to fix and avoid them. Design shortcomings we will discuss include: Flow […]

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How to Stop Flash in Injection Molding?

Troubleshooting flash is complicated, and often there is a lot of tail-chasing on the shop floor in trying to get a solution. This approach should lead you to the solution via a data-driven procedure. Testing the parting line, using pressure-indicating paper: The image on the left is flash-free. The part on the right side is flashed; note the location of flash where the paper is mostly white at the top and bottom. The white color indicates the parting-line touch force […]

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