Materials processing and techniques

Materials Processing Methods

Casting: A process where a liquid material is poured into a mould that has been shaped as the inverse of the desired product. Once the liquid hardens, it takes the shape of the mould.
Injection Moulding: A manufacturing process for producing parts by injecting molten material into a mould. The mould cavity is created using two hardened tool steel dies.
Extrusion: A process used to create objects of a fixed cross-sectional profile. A material is pushed through a die of the desired cross-section.
3D printing (additive manufacturing): A process of making three dimensional solid objects from a digital file. The creation of a 3D printed object is achieved using additive processes.

Adhesive bonding: An industrial joining method whereby two surfaces are held together by a layer of adhesive.
Welding: A fabrication process that joins materials, usually metals or thermoplastics, by using high heat to melt the parts together, allowing them to cool and cause fusion.
Soldering: A process in which two or more items are joined together by melting and putting a filler metal into the joint.
Riveting: A mechanical fastening process characterised by the use of a tubular, eyelet-like fastener with a round head.
Brazing: A metal-joining process whereby a filler metal is heated above melting point and distributed into the joint between two close-fitting parts by capillary action.

Sanding: The process of using abrasive materials to smoothen surfaces.
Polishing: A process aimed at creating a smooth and shiny surface by rubbing it or applying a chemical treatment.
Painting: Applying a layer of paint on the surface for protection and aesthetics.
Varnishing: Applying varnish for protection and to enhance appearance.
Powder coating: A type of coating that is typically applied as a free-flowing, dry powder. The coating is applied electrostatically and is then cured under heat to allow it to flow.

Annealing: A heat treatment process that alters the microstructure of a material to change its mechanical or electrical properties, especially hardness and brittleness.
Tempering: A process of heat treating, which is used to increase the toughness of iron-based alloys. The process creates a balance between hardness and toughness.
Quenching: Rapidly cooling material to increase its hardness.
Hardening: A process of making a material, particularly a metal, physically harder.

CNC (Computer Numerical Control): A method used in manufacturing that involves the use of computers to control machine tools. Examples of these tools include lathes, mills, routers and grinders.
The G-Code in CNC machining is a language in which people tell computerized machine tools how to make something by defining all machine tool paths.
CNC milling is a specific form of computer numerical controlled machining involving the use of cutting tools to remove material from a workpiece.
CNC lathing involves using a cutting tool that takes a helical path to remove material from the workpiece.