manufacturing processes Flashcards
(18 cards)
What is Injection Moulding?
Molten plastic is injected into a mould, cooled, and ejected as a solid part. Used for: Mass production of plastic parts
advantages and disadvantages of injection moulding
Advantages: Fast, repeatable, precise, low waste.
Disadvantages: High initial mould cost.
What is Blow Moulding?
Process: Air is blown into a heated plastic tube inside a mould to form hollow shapes.
Used for: Bottles, containers, tanks.
advantages and disadvantages of blow moulding
Advantages: Good for hollow parts, low material cost.
Disadvantages: Limited to thin-walled items.
What is Vacuum Forming?
Process: A heated plastic sheet is draped over a mould; vacuum pulls it tightly to form the shape.
Used for: Packaging, trays, disposable cups.
advantages and disadvantages of vacuum forming
Advantages: Low cost, fast setup.
Disadvantages: Limited to shallow, simple shapes.
What is 3D Printing (Additive Manufacturing)?
Process: Builds parts layer by layer from a digital model, using materials like plastic, resin, or metal.
Used for: Prototypes, custom parts, small batch production
advantages and disadvantages of 3D printing
Advantages: Rapid prototyping, complex shapes possible.
Disadvantages: Slower for mass production, limited material strength.
What is CNC Machining?
Process: Computer-controlled tools cut and shape solid materials (e.g., metal, plastic).
Used for: Precision parts in aerospace, automotive, medical devices.
advantages and disadvantages of CNC machining
Advantages: High accuracy, excellent finish.
Disadvantages: High setup cost, waste from material removal.
What is Die Casting?
Process: Molten metal is forced into a steel mould under high pressure.
Used for: Complex metal parts (e.g., engine blocks, housings).
advantages and disadvantages of Die casting
Advantages: High volume, smooth finish, good dimensional accuracy.
Disadvantages: Expensive tooling, limited to non-ferrous metals.
What is Extrusion?
Process: Material is pushed through a shaped die to create long parts with a constant cross-section.
Used for: Pipes, rods, window frames.
advantages and disadvantages of extrusion
Advantages: Continuous process, low scrap, good for high-volume production.
Disadvantages: Limited to uniform cross-sections.
What is Powder Metallurgy?
Process: Metal powders are compressed into a shape and then heated to fuse particles together.
Used for: Gears, filters, structural parts.
advantages and disadvantages of powder metallurgy
Advantages: Minimal waste, complex shapes possible.
Disadvantages: High material cost, weaker than cast or forged parts.
What is Forging?
Process: Metal is shaped by applying compressive force, often while heated.
Used for: Tools, crankshafts, aerospace parts
advantages and disadvantages of forging
Advantages: Very strong parts, good for fatigue resistance.
Disadvantages: Expensive dies, less suitable for complex shapes
