Methods of processing materials

The principles of material processing reflect the changes and alterations made to materials in order to achieve the desired design.
It is essential to understand the properties and characteristics of different materials to select an appropriate processing method.
Techniques can vary from simple cutting and shaping to complex chemical or heat-induced changes.
The manufacturing process chosen should be both cost effective and suitable for the design requirements.

Casting: This involves pouring molten or liquid material into a mould where it cools and hardens into the desired shape.
Moulding: Similar to casting, but typically involves the use of thermoplastics or elastomers. The material is heated until plastic, then forced into a mould where it cools.
Forming: This includes bending, stretching, or compressing material to a new shape, often with the use of dies or punches.

Cutting: This procedure can be carried out by hand tools or mechanised devices like lasers or water jets. The method depends on the material type and necessary precision.
Machining: The use of machine tools to remove undesired material from a piece, also referred to as subtractive manufacturing.
Joining: This includes both temporary (bolting, nailing) and permanent (welding, soldering) methods to join two or more pieces together.
Finishing: This final step can include sanding, polishing or painting the product for a professional and protective finish.

Computer Numerically Controlled (CNC) machining: Highly precise, typically used for complex parts or high volume production.
Additive manufacturing (3D printing): A newer technology that allows for highly complex geometries and customised designs.
Laser cutting/engraving: Allows for high-precision cutting and decorative detailing.
Plasma cutting: An advanced technique used to cut high-strength materials, like steel or titanium.

When processing materials, health and safety is paramount - proper Personal Protective Equipment (PPE) should always be worn.
Risk assessments should be completed before beginning any new process or using unfamiliar equipment.
Good housekeeping and maintenance of workspaces reduces the risk of accidents.
All operations and equipment use should be carried out in accordance with manufacturer’s instructions.