How to manufacture parts for production

In this article, we’ll take a look at some of the technologies and materials used to manufacture parts for production, their benefits, things to consider and more.

Introduction

Manufacturing parts for production – also known as end-use parts – refers to the process of using raw materials to manufacture parts that is designed and manufactured to be used in a final product, as opposed to a prototype or model. Read our guide to making initial prototypes to find out more.

To ensure that your parts work in the real world – as machine parts, vehicle components, consumer products or for any other functional purpose – manufacturing must be approached with this in mind. To successfully and efficiently manufacture parts for production, you should consider materials, design and production methods to ensure you meet the necessary functional, safety and quality requirements.

Selecting materials for production parts

Common materials for manufacture parts include metals such as steel or aluminium, plastics such as ABS, polycarbonate and nylon, composites such as carbon fibre and glass fibre, and certain ceramics.

The right material for your end-use parts will depend on the specific requirements of the application, as well as cost and availability. Here are some common properties to consider when selecting materials for production parts:

Strength. Materials should be strong enough to withstand the forces to which a part will be subjected during use. Metals are good examples of strong materials.
Durability. Materials should be able to withstand wear and tear over time without degrading or breaking down. Composites are known for both durability and strength.
Flexibility. Depending on the application of the final part, a material may need to be flexible to accommodate movement or deformation. Plastics such as polycarbonate and nylon are known for their flexibility.
Temperature resistance. For example, if the part will be exposed to high temperatures, the material should be able to withstand the heat without melting or deforming. Steel, ABS and ceramics are examples of materials with good temperature resistance.

Manufacturing methods for parts for production

Four types of manufacture parts methods are used to create parts for production: subtractive manufacturing, additive manufacturing, metal forming, and casting.

Subtractive manufacturing

Subtractive manufacturing – also known as traditional manufacturing – involves removing material from a larger piece of material until a desired shape is achieved. Manufacturing is often faster than additive manufacturing, making it more suitable for high-volume batch production. However, it can be more expensive, especially when tooling and set-up costs are taken into account, and generally produces more waste.

Computer Numerical Control (CNC) Milling. A type of CNC machining, CNC milling uses a cutting tool to remove material from a solid block to create a finished part. It is capable of producing parts with a high degree of accuracy and precision in materials such as metals, plastics and composites.
CNC turning. Also a type of CNC machining, CNC turning uses a cutting tool to remove material from a rotating solid. It is typically used to produce objects that are cylindrical, such as valves or shafts.
Sheet metal fabrication. Sheet metal fabrication involves cutting or forming a flat sheet of metal to a design, usually a DXF or CAD file.

Additive manufacturing

Additive manufacturing – also known as 3D printing – is the process of adding material to create a part. It can produce highly complex shapes that would otherwise be impossible with traditional (subtractive) manufacturing methods, produces less waste, and can be faster and cheaper, especially when producing small batches of complex manufacture parts. However, producing simple parts can be slower than subtractive manufacturing and the range of materials available is generally narrower.

Stereolithography (SLA). Also known as resin 3D printing, SLA uses UV lasers as a light source to selectively cure a polymer resin to create a finished part.
Fused Deposition Modelling (FDM). Also known as Fused Filament Fabrication (FFF), FDM builds parts layer by layer by selectively depositing molten material along a predetermined path. It uses thermoplastic polymers that come in filaments to form the final physical objects.
Selective Laser Sintering (SLS). In SLS 3D printing, a laser selectively sinters the particles of a polymer powder, fusing them together and building a part layer by layer.
Multi Jet Fusion (MJF). HP’s proprietary 3D printing technology, MJF can consistently and quickly deliver parts with high tensile strength, fine feature resolution and well-defined mechanical properties.

Metal forming

Metal forming is the process of forming metal into a desired shape by applying force using mechanical or thermal methods. The process can be either hot or cold, depending on the metal and the desired shape. Parts produced by metal forming typically have good strength and durability. It also tends to produce less material waste than other forms of manufacturing.

Forging. Metal is heated and then formed by applying pressure.
Extrusion. Metal is forced through a die to create a desired shape or profile.
Drawing. Metal is pulled through a die to create a desired shape or profile.
Bending. Metal is bent into a desired shape by an applied force.

Casting

Casting is a manufacturing process in which a liquid material, such as metal, plastic or ceramic, is poured into a mould and allowed to solidify into a desired shape. It is used to produce parts with a high degree of accuracy and repeatability. Casting is also a cost-effective choice for high volume production.

Injection Moulding. A manufacturing process used to produce parts by injecting molten material – often plastic – into a mould. The material is then cooled and solidified, and the finished part is ejected from the mould.
Die casting. Die casting involves forcing molten metal under high pressure into a mould cavity. Die casting is used to produce complex shapes with high accuracy and repeatability.

Tips for using DFM analysis to minimise the cost of your production run

Minimise components. Typically, the fewer components a part has, the lower the assembly time, the lower the risk or error, and the lower the overall cost.
Availability. Parts that can be manufactured using existing production methods and equipment – and that have relatively simple designs – are easier and cheaper to produce.
Materials and components. Parts that use standard materials and components can help reduce costs, simplify supply chain management and ensure that spare parts are readily available.
Part orientation. Consider the orientation of the part during production. This can help minimise the need for supports or other additional features that can increase overall production time and cost.
Avoid undercuts. Undercuts are features that prevent a part from being easily removed from a mould or fixture. Avoiding undercuts can help reduce production time and costs and improve the overall quality of a finished part.

The cost of manufacturing parts for production

Striking a balance between quality and cost is key in manufacturing parts meant for production. Here are several cost-related factors to consider:

Raw materials. The cost of raw materials used in the manufacturing process depends on the type of material used, its availability and the quantity required.
Tooling. Includes the cost of machinery, moulds and other specialised tools used in the manufacturing process.
Volume of production. In general, the higher the volume of parts you produce, the lower the cost per part. This is particularly true for injection moulding, which offers significant economies of scale for larger volumes.
Lead times. Parts produced quickly for time-sensitive projects often have higher costs than those with longer lead times.

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Are you looking for a reputable partner for your manufacture parts fabrication and machining projects? Look no further. At PROTO MFG, we specialize in CNC machining and related technologies, including sheet metal fabrication, rapid prototyping, etc. Whether it is a project with a simple design or parts with complex geometries, do not hesitate to contact us today!