4.4 Manufacturing Processes

Examples of Additive techniques

**Paper-based rapid prototyping**

**Laminated object manufacture (LOM)**

**Stereolithography**

Paper-based rapid prototyping

Layers of paper cut and glued together to create a 3D shape. Low-fidelity.

Laminated object manufacture (LOM)

3D printing technique that involves the layer-by-layer construction of objects using sheets of material, typically paper, plastic film, or metal foil

Stereolithography

Solidification of powder using 3D printing

Examples of subtractive techniques

**Cutting** (Laser, Saws, Chiseling, Drilling) 

**Machining** (Router or Milling machine) 

**Turning** (Metal or Wood Lathe) 

**Abrading** (Sanding, Filing, Grinding)

Examples of shaping techniques

**Moulding**

**Thermoforming**

**Laminating**

**Knitting**  

**Weaving**

Moulding

Injection moulding, extrusion

Thermoforming

Heating plastics and vacuum forming, or using a strip heater to heat and bend acrylic

Laminating

Flexi-plywood by gluing layers together over a former/shaped mould

 **Casting**

Sand casting, Die casting- usually solid to liquid then cooled 

Examples of Joining techniques

**Permanent**

**Temporary**

**Adhering- Gluing** 

**Fusing (welding)** 

Permanent

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Methods used to permanently bond or join materials together, creating a strong and lasting connection.

e.g. Welding, Brazing, Soldering (joining metals by melting a filler metal), Pop riveting

**Adhering- Gluing** 

once formed, cannot easily be separated 

**Fusing (welding)** 

Permanent process involving the heating of the surfaces such as metals and plastics. This process isn’t recommended when considering design for disassembly

Temporary

(non-permanent fastening) 

Fastening or joining materials mechanically through the use of screws, rivets, bolts, pins, clips, nails, press studs and snaps.

Adv and Disadvantages of permanent vs temporary

Temporary:

ease for disassembly at the expense of permanent damage to the materials used eg. installing screws 

Adjustability: Temporary joining methods offer flexibility in terms of adjustment and alignment of the joined parts.

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Permanent:

Strength and durability: Permanent joining techniques, such as welding or adhesive bonding, can create strong and durable connections between materials.

Seamless appearance

Load distribution: Permanent joining techniques distribute the load across the entire joint, minimizing stress concentration.