Solutions to Manufacture Parts for Production

The process of using raw materials to create a part that is intended to be used in a final product rather than a prototype or model is referred to as manufacturing parts for production, or end-use parts. For additional information on manufacturing prototypes, see our blogs.

To guarantee that your parts perform as intended in an actual setting, such as on consumer goods, auto parts, machinery, or any other functional application. This is something to keep in mind when approaching manufacturing. You should think about materials, design, and production techniques to successfully and efficiently manufacture parts for production, making sure you meet the essential functional, safety, and quality requirements.

This article will examine various technologies and materials used in production part manufacturing, along with their advantages, considerations, and other related topics.

Choosing Materials for Production Parts

When it comes to selecting materials to manufacture parts for production, there are several options available. Commonly used materials include metals like steel or aluminum, plastics such as ABS, polycarbonate, and nylon, composites like carbon fiber and fiberglass, and certain ceramics.

The choice of material for your end-use parts depends on various factors, including specific application requirements, cost considerations, and material availability. To make an informed decision, here are some key properties to consider when selecting materials to manufacture parts for production:

• Strength: The material should possess sufficient strength to endure the forces it will encounter during use. Metals, such as steel, are renowned for their strength and are commonly employed in this regard.
• Durability: The selected material should be capable of withstanding wear and tear over time without deteriorating or breaking down. Composites are often favored for their durability and strength, making them a viable option.
• Flexibility: Depending on the intended application of the final part, flexibility may be a crucial factor. Some materials, like polycarbonate and nylon, are known for their flexibility, allowing them to accommodate movement or deformation when required.
• Temperature Resistance: If the part is expected to be exposed to high temperatures, it is essential to choose a material that can withstand the heat without melting or deforming. Materials such as steel, ABS, and ceramics exhibit excellent temperature resistance characteristics.

By carefully considering these properties, you can select the most suitable material for your production parts that meets the specific needs of your application.

Manufacturing Methods for Production Parts

There are four primary manufacturing methods employed to manufacture parts for production: subtractive manufacturing, additive manufacturing, metal forming, and casting.

Subtractive Manufacturing

Subtractive manufacturing, also known as traditional manufacturing, involves the removal of material from a larger piece until the desired shape is achieved. It is often faster than additive manufacturing, making it suitable for high-volume batch production. However, it can be more expensive due to tooling and setup costs and tends to generate more waste.

Common types of subtractive manufacturing include:

• Computer Numerical Control (CNC) milling:
  This technique utilizes a cutting tool to remove material from a solid block, producing accurate and precise parts in various materials like metals, plastics, and composites.
• CNC turning:
  In CNC turning, a cutting tool removes material from a rotating solid, often used for creating cylindrical objects such as valves or shafts.
• Sheet metal fabrication:
  This process involves cutting or forming a flat sheet of metal according to a blueprint, typically in a DXF or CAD file format.

Additive Manufacturing

Additive manufacturing, also known as 3D printing, involves adding material layer by layer to construct a part. It is capable of producing intricate shapes that are challenging to achieve with traditional manufacturing methods. Additive manufacturing generates less waste and can be more cost-effective, especially for small batches of complex parts. However, it may be slower for creating simple parts and has a narrower range of available materials.

Common types of additive manufacturing include:

• Stereolithography (SLA):
  Also known as resin 3D printing, SLA uses UV lasers to selectively cure a polymer resin and create the final part.
• Fused Deposition Modeling (FDM):
  FDM builds parts layer by layer by selectively depositing melted material along a predetermined path. It utilizes thermoplastic polymers in filament form.
• Selective Laser Sintering (SLS):
  SLS 3D printing employs a laser to selectively fuse polymer powder particles, layer by layer, creating the desired part.
• Multi Jet Fusion (MJF):
  MJF is HP’s proprietary 3D printing technology, capable of consistently and rapidly delivering parts with high tensile strength, fine feature resolution, and well-defined mechanical properties.

Metal Forming

Metal forming involves shaping metal into the desired form by applying force through mechanical or thermal methods. The process can be conducted at hot or cold temperatures, depending on the metal and desired shape. Parts created through metal forming typically exhibit excellent strength and durability, while generating less material waste compared to other methods to manufacture parts for production.

Common types of metal forming include:

• Forging: Metal is heated and then shaped by applying compressive force to it.
• 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 to the desired shape through the application of force.

Casting

Casting is a manufacturing process that involves pouring a liquid material, such as metal, plastic, or ceramic, into a mold. The material is then allowed to solidify and take the shape of the mold. Casting can manufacture parts for production with high precision and repeatability, making it a cost-effective choice for large-batch production.

Common types of casting include:

• Injection molding:
  This process is used to manufacture parts by injecting molten material, often plastic, into a mold. The material is then cooled and solidified, and the finished part is ejected from the mold.
• Die casting:
  In die casting, molten metal is forced into a mold cavity under high pressure. It enables the production of complex shapes with high accuracy and repeatability.

Design for Manufacturability and Parts for Production

Design for manufacturability (DFM) is an engineering approach that prioritizes designing parts or tools with a focus on efficient and cost-effective production. By utilizing automatic DFM analysis, engineers and designers can create, iterate, simplify, and optimize parts before manufacturing, leading to improved efficiency throughout the production process. Designing parts that are easier to manufacture can reduce production time, costs, and the risk of errors and defects in the final products.

Tips for Using DFM Analysis in Production Run

Here are some tips for using DFM analysis to minimize production costs:

• Minimize components:
  Reducing the number of components in a part decreases assembly time, lowers the risk of errors, and reduces overall costs.
• Consider manufacturing methods and equipment availability:
  Opt for readily available production methods and equipment to manufacture parts for production. Simpler designs are generally easier and less expensive to produce.
• Standard materials and components:
  Design and manufacture parts that utilize standard materials and components. This helps reduce costs, simplifies supply chain management, and ensures easy availability of replacement parts.
• Part orientation:
  Take into account the orientation of the part during production. By optimizing the orientation, the need for additional features like supports can be minimized, reducing production time and costs.
• Avoid undercuts:
  Undercuts are features that make it difficult to remove a part from a mold or fixture. By avoiding undercuts in the design, production time and costs can be reduced, while enhancing the overall quality of the final part.

Cost of Manufacturing Parts for Production

By implementing these DFM strategies to manufacture parts, manufacturers can streamline their production processes, improve cost-efficiency, and enhance the overall quality of the manufactured parts.
Managing the cost of manufacturing parts for production requires finding the right balance between quality and expense. Consider the following factors that influence costs:

• Materials: The choice of raw materials affects manufacturing costs. Factors such as material type, availability, and required quantity impact the overall expense.
• Tooling: The cost of machinery, molds, and specialized tools necessary for the manufacturing process should be considered. These upfront investments contribute to the overall cost of production.
• Production volume: Generally, producing a larger volume of parts results in a lower cost per part. This is particularly evident in processes like injection molding, where economies of scale play a significant role in reducing costs for larger order volumes.
• Lead times: To manufacture parts quickly for meeting tight project timelines often involve higher costs compared to those with longer lead times. Expedited production incurs additional expenses to ensure timely delivery.

By carefully evaluating and managing these cost-related factors, manufacturers can optimize their processes to manufacture parts for production, control expenses, and strike a balance between quality and cost-effectiveness.

Manufacture Parts for Production from Sungplastic

Sungplastic solutions to manufacture parts for production include:
CNC machining
Injection molding
Die casting
Low volume manufacturing
High volume manufacturing
Sheet metal stamping
Rapid prototyping
Mold fabrication
Surface finishing
…
If you are not sure what method to choose to manufacture parts for production, please contact us.
Welcome to discuss your ideas with us and get an instant quote to compare pricing and lead times for your production parts.

FAQs

What advantages does subtractive manufacturing offer?
Extensive material options, accuracy, and precision are advantages of subtractive manufacturing. Additionally, it lowers the possibility of parts losing their mechanical strength by enabling engineers to work with materials at low temperatures.

What advantages does additive manufacturing offer?
One of additive manufacturing’s advantages is its speed and efficiency in producing customized parts and intricate geometries.

Is it costly to manufacture parts for production?
Equipment and material investments are necessary to manufacture parts for production, but there are ways to cut costs, such as optimizing your design for economical production with DFM analysis. Remember that the cost per part for many manufacturing processes, like injection molding, decreases with increasing order volume.

How can the cost of producing parts for production be reduced?
By streamlining the supply chain and logistics, cutting waste, employing effective technologies, and improving manufacturing processes, you can minimize the costs associated with producing parts for production.