Manufacturing Processes Guides

Wire EDM vs sinker EDM: geometry capability, tolerance, recast layer, electrode cost, mold tooling applications & DFM guidelines for engineers.

Dry etching vs wet etching: isotropic vs anisotropic, feature size limits, aspect ratios, DRIE, material compatibility, CD tolerance & manufacturing cost comparison.

Pad printing process: how it works, material compatibility, ink adhesion, durability vs laser marking, common defects, DFM guidelines & cost structure.

Wire EDM process guide: how it works, ±0.002–0.005 mm tolerances, materials, wire EDM vs CNC milling vs laser cutting, DFM guidelines & cost drivers.

Electroforming is a plating process used on non-conductive surfaces. The electroformed objects can serve as molds or encapsulations. It is an extremely precise technique for replicating the geometry of sheets.

Centrifugal casting is low-cost and suitable for casting metals, plastics, composites, and glass. With very low mold costs, this process is used for prototyping and mass-producing millions of parts.

This simple and versatile process is used to bend metal sheets for prototyping and mass production. It can form geometric shapes such as bends, stretches, and flakes. This process is also known as bending forming.

With CNC (Computer Numerical Control) machining, you can directly import CAD (Computer-Aided Design) data into the workbench. CNC machining uses milling machines, lathes, and planers throughout the process.

This layer-by-layer process can be used for single-prototype forming or small-batch production directly from CAD data. Since it doesn't involve molds, it helps reduce costs and offers many advantages for designers.

This is a highly precise CNC machining process. It can be used to cut, etch, engrave, and mark various sheet materials, including metals, plastics, wood, textiles, glass, ceramics, and leather.

Round, square, and irregular holes are cut into sheet materials using quenched steel punches. Depending on the design's shape and complexity, the tools can be either custom-made or interchangeable.

This process combines powder metallurgy with injection molding. It is suitable for producing small parts made of steel, stainless steel, magnetic alloys, bronze, nickel alloys, and cobalt alloys.

In this process, liquid metal forms complex and intricate shapes using non-permanent ceramic molds, also known as lost-wax casting.

Die casting is an accurate way to shape metal parts. This high-speed process uses pressure to push molten metal into reusable steel molds, making complex 3D shapes.

Molten metal is poured into disposable sand molds here. Once the metal hardens, the sand molds are broken to remove the shaped parts. This process is relatively inexpensive for making one-off or small batches of parts and works for casting various ferrous and non-ferrous alloys.