Injection molding is an excellent manufacturing method for large scale production. It is most often used in processes of thousands or even millions of units with highly accurate and repeatable results. Thermoplastic resin is heated and injected into the preformed mold, cooled and ejected resulting in the desired design.
Compression molding is accomplished by utilizing pressure and heat to form thermoplastic or other materials in a mold. Tooling costs are generally lower than injection molding, but the process can be slower, a factor to be considered for large volume production runs.
Die casting is similar to injection molding, however die casting separates itself by the use of metal materials. Hot molten metal is forced into a mold cavity made of two hardened steel dies. This process is ideally suited for high-volume production due to the higher tooling cost of the casting molds.
Die cutting is the process utilizing a cutting instrument to product the desired shape in a material. This material can either be a metal, polymer, or even organic substances like you would find the food industry.
The process can be accomplished with a traditional stamping mechanism, or a rotary cutter with a cylindrical die on a rotary press. This is a rapid process and allows for a continuous feed of material in sheet form.
Metal stamping involves placing a “blank”, flat sheet metal or even polystyrene into a press containing a die to form the metal into the desired shape.
Forging is a manufacturing process which usually involves heated metal “ingots” subjected to compressive forces. This process is ideal for products requiring high-strength and usually requires subsequent machining processes to refine the finished product.
The extrusion process involves compressing a blank of raw material through a die to achieve the desired cross-sectional profile. The advantage of this process is the ability to make highly complex shapes and to form lengths that can be continuous.
Machining is the process by which raw material is cut into a final shape. This is typically done by a CNC machine. Often, these processes are used in the creation of machine tools such as molds used in other manufacturing processes.
Powder coating finishes are a highly durable and effective option for many companies and product types around the world. The process involves applying dry powder through electrostatics to the product surface, followed by a curing process typically with heat.