A beginner's guide to metal manufacturing

Are you ready to go to mass production with your metal components but don't know where to start? This beginner's guide to metal manufacturing explains types of metal manufacturing and each type's metal options, run sizes, and pros and cons.

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SIMPLE: Using Metal Coils or Strips
Stamping: Forming metal coils or strips into shapes (blanks, embosses, and bends, for example) using a press (a single operation or a series of stages)
Metals used:

• Aluminum
  
• Electrolytic steel
  
• Stainless steel
  

For large runs (10,000+ parts)
Pros: Rapid production time (seconds) and most cost-effective part pricing
Cons: Tooling generally costs from $10,000 to $50,000, and tooling changes are limited.

Laser Cutting: Cutting and etching metal using a laser, usually through optics and CNC (Computer Numerical Control) for material or laser beam control. The process leaves a high-quality surface finish and permanently etched parts.
Metals used:

• Aluminum
  
• Sheet steel
  
• Stainless steel
  

For small runs (less than 10,000 parts)
Pros: No tooling needed
Cons: Slower process with longer turnaround time and higher prices

COMPLEX: Using Bar Stock or Melted Metal
Die Casting: Putting liquid metal into a mold under high pressure, commonly used for the production of complex geometries.
Metals used:

• Aluminum
  
• Copper
  
• Lead
  
• Magnesium
  
• Tin
  
• Zinc
  

For large runs (10,000 parts)
Pros: Rapid production time (seconds) and cost-effective part pricing
Cons: Tooling generally costs from $10,000 to $50,000, and tooling changes are limited.

Machining: Drilling and threading bar stock, commonly used in production of nuts.
Metals used:

• Aluminum
  
• Brass
  
• Stainless steel
  

For large runs (10,000+ parts)
Pros: Little or no tooling needed
Cons: Slower process with longer turnaround time and higher prices

Want to know more? Contact Curtis: 508-845-6501 x306 or sales@donahueindustries.com.