HL A4.1 Manufacturing Techniques

3D printing

The process of creating physical objects from a 3D digital model layer by layer.

4D printing

The process of using 3D printing to create a physical object that is able to change its shape or properties when exposed to a stimulus such as water, air, heat or an electric current.

5D printing

Similar to 3D printing in that it is a process of printing multiple thin layers of a material, 5D printing has a rotating extruder head that can print on 5 axes.

Abrading

A process where the surface of a material is rubbed away with another material.

Additive manufacturing

Manufacturing techniques that add material in order to create an object.

Adhering

A process where the surfaces of two materials are permanently joined together using a third material such as glue.

Anodizing

An electrochemical process that creates a thick oxidized coating on the surface of a component, which is usually made from aluminium or one of its alloys.

Casting

The process of creating an object by filling a mould with a molten material.

Computer-aided design (CAD)

The use of computer software to aid the design process.

Die-casting

Used to produce products typically made from non-ferrous metals (such as aluminium, zinc and magnesium) using a mould cavity into which molten metal is injected under high pressure. This process is known for its ability to produce parts with high precision and excellent surface finish.

Electroplating

A process used to create a metal coating on the surface of a product using a chemical reaction triggered by an electric current.

Fastening

A device that secures one material to another.

Finishing techniques

A manufacturing process used to finalize the surface of a component in order for it to be bonded to another, to improve its aesthetics or provide durability.

Form

In the context of product design, form relates to the shape of a product and the aesthetic qualities that the shape gives.

Forming techniques

Mechanical processes used in manufacturing to reshape material without removing or adding any of that material. Examples of forming techniques include extrusion, stamping, bending and injection moulding.

Fused deposition modelling (FDM)

A 3D rapid prototyping printing methodology that deposits melted layers of material on a bed to build up a 3D model.

Galvanizing

A finishing process that applies a layer of zinc to the surface of steel or iron to prevent rusting.

Injection moulding

Used to produce parts or products by injecting molten material into a mould cavity. Common materials used include thermoplastics (e.g. ABS, polyethylene, polypropylene), thermosetting plastics (e.g. epoxy, phenolic) and elastomers (e.g. rubber).

Joining techniques

Methods that are used to join two similar or dissimilar materials together.

Laminated object manufacture (LOM)

A system that virtually slices a 3D CAD model into thin layers, then cuts out each layer from a roll of material using a laser or plotter cutter.

Machining (manufacturing)

The act of manufacturing a component using a machine.

Manufacturing techniques

The methods of processing raw materials into products and components using tools, human labour, machinery and chemical processes.

Mass customization

A sophisticated CIM system that manufactures products to individual customer orders, gaining economy of scale for any order size.

Material extrusion

The process of forming a material by forcing it through a die, resulting in objects with a fixed cross-section.

Moulding

A suite of manufacturing techniques that uses a mould to shape material into a desired form.

Polishing

A finishing technique where the surface of a material is made smooth and shiny by rubbing it.

Powder bed fusion (PBF)

An additive manufacturing technique where directed thermal energy is used to fuse material together in layers to create a 3D object.

Press-forming

A manufacturing process where a material is pressed into a mould to create an object or component.

Rapid prototyping

A group of manufacturing techniques used to manufacture a physical object quickly for testing aspects of a product, typically using CAD models.

Scale of production

Refers to the classification of a production system by the number of products that are to be made.

Selective laser sintering (SLS)

An additive manufacturing technique that uses a laser to fuse small particles of material into a mass that has a desired 3D shape.

Stereolithography (SLA)

An additive manufacturing technique that creates 3D models layer by layer by hardening molecules of a photosensitive liquid polymer using a laser beam.

Stitching

The action of using a corded or threaded material to loop two or more materials together.

Subtractive manufacturing

Manufacturing techniques that cut away material in order to create a component.

Weaving

The act of forming a sheet-like material by interlacing long threads passing in one direction with others at a right angle to them.

Welding

A manufacturing process used to join parts by heating them to melting point and allowing them to solidify together.