PRODUCTION TECHNIQUES

On this page we will give you an idea of what these production techniques are, how they work, and what you can make with them. Some parts and products require multiple techniques. We will inform you on the steps needed to make your product and keep you posted all the way until the finished product is ready.

Rubber injection moulding

Rubber injection moulding is a manufacturing process used to produce precise and complex rubber parts in high volumes. It involves injecting heated, uncured rubber into a closed mould cavity, where it is shaped and cured to form the final product. This method is ideal for making consistent, durable rubber components with intricate details.

Process Steps:

Preparation of Raw Material
The rubber material (usually in a pellet or strip form) is pre-heated and prepared for injection. It's typically a thermoset rubber compound, which requires curing to set its final shape.
Injection into Mould Cavity
The pre-heated rubber is injected under high pressure into a pre-heated metal mould cavity using a screw or plunger system. This ensures the material fills the entire mould quickly and uniformly.
Curing (Vulcanization)
Once inside the mould, the rubber is subjected to heat and pressure for a set period. This causes a chemical reaction called vulcanization, which transforms the rubber into a solid, durable, and elastic material.
Cooling and Ejection
After curing, the mould is cooled, and the finished rubber part is ejected from the mould cavity. The part is then trimmed if necessary to remove any flash or excess material.
Post-Processing (Optional)
Depending on the application, additional finishing processes like deflashing, surface treatment, or inspection may be performed.

Plastic injection moulding

Plastic injection moulding is a widely used manufacturing method for producing high-precision plastic parts in large quantities. It involves melting plastic pellets and injecting the molten plastic into a mould, where it cools and solidifies into the desired shape. This process is ideal for making everything from simple items like bottle caps to complex components for automotive, medical, and electronic applications.

Process Steps:

Plastic Pellet Feeding
Thermoplastic pellets (such as ABS, polyethylene, or polypropylene) are fed into a hopper, which directs them into a heated barrel.
Melting and Mixing
Inside the barrel, a rotating screw heats and mixes the plastic until it melts into a homogeneous, flowable state.
Injection into Mould
The screw then moves forward, injecting the molten plastic into a metal mould cavity at high pressure. The mould is precisely machined to the shape of the final part.
Cooling and Solidification
Once the cavity is filled, the mould is kept closed while the plastic cools and solidifies. Cooling time depends on part size, design, and material.
Mould Opening and Part Ejection
After sufficient cooling, the mould opens, and ejector pins push the finished part out of the mould.
Post-Processing (Optional)
Some parts may require trimming, assembly, or surface finishing. Quality control checks are also performed at this stage.

CNC

CNC machining is a manufacturing process where pre-programmed computer software controls the movement of tools and machinery to shape materials like metal, plastic, wood, or composites. It is widely used for creating precise parts and components in industries such as aerospace, automotive, electronics, and medical devices.

Process Steps:

Design Creation (CAD)
The process begins with a CAD (Computer-Aided Design) model of the part. This digital blueprint contains all the necessary dimensions and specifications.
Program Conversion (CAM)
The CAD file is converted into a CNC program using CAM (Computer-Aided Manufacturing) software. This program contains G-code, which tells the machine how to move.
Machine Setup
The operator sets up the raw material (also called a workpiece) on the machine bed and installs the necessary cutting tools.
Machining Process
The CNC machine automatically performs cutting, drilling, milling, turning, or grinding operations based on the programmed instructions. It moves the tools with high precision and speed along multiple axes (X, Y, Z, and sometimes more).
Finishing and Inspection
Once machining is complete, the part may undergo finishing operations like deburring, polishing, or coating. It is then inspected to ensure it meets quality and dimensional standards.

Benefits of CNC Machining:

High precision and repeatability
Ability to produce complex geometries
Efficient for both prototyping and mass production
Reduced human error and consistent quality
Lower MOQ then moulding techniques

Turning

Turning is a machining process used to create cylindrical parts by removing material from the outer surface of a rotating workpiece. It is typically performed on a lathe, one of the oldest and most fundamental machine tools in manufacturing.

Process Steps:

Workpiece Mounting
A cylindrical or round-shaped workpiece is securely clamped into the lathe’s chuck. The chuck rotates the workpiece at high speed.
Tool Engagement
A cutting tool (usually made of carbide or high-speed steel) is fed against the rotating workpiece in a controlled manner. The tool removes material in the form of chips to achieve the desired shape and size.
Material Removal
Turning can involve several operations such as:
- Facing – cutting across the end of the part to create a flat surface
- Straight Turning – reducing the diameter
- Taper Turning – creating a conical shape
- Grooving or parting – cutting narrow grooves or separating a part
- Threading – forming screw threads
Finishing
After rough cutting, finishing passes may be done to improve surface quality and dimensional accuracy.

Types of Turning:

Manual Turning – operated by a machinist using a conventional lathe
CNC Turning – automated with a computer program for high precision and repeatability

Applications:

Turning is used to manufacture shafts, rods, pins, bushings, bolts, and other round components used in automotive, aerospace, and industrial equipment.

Casting

Casting is a manufacturing method where liquid material is poured into a hollow mould and allowed to solidify into a specific shape. Once the material hardens, the mould is removed, revealing a finished or near-finished part. Casting is one of the oldest and most versatile manufacturing processes, used to make complex shapes that would be difficult or uneconomical to produce by other means.

Process Steps:

Pattern Creation
A pattern is made in the shape of the final product. This can be made from wood, plastic, or metal and is used to form the cavity in the mould.
Mould Making
The mould is created around the pattern. It can be made from sand, metal, ceramic, or other materials, depending on the type of casting process.
Melting and Pouring
The chosen material—often metal (like aluminum, iron, or steel), plastic, or resin—is melted and then poured into the mould cavity.
Cooling and Solidification
The molten material cools and hardens inside the mould, taking its shape.
Mould Removal
Once solidified, the mould is opened or broken apart to remove the casting. This can be done manually or automatically.
Finishing
The casting may go through trimming, machining, heat treatment, or surface finishing to meet final specifications.

Types of Casting:

Sand Casting – inexpensive and flexible, used for large parts
Die Casting – high-pressure method for making high-volume, detailed parts
Investment Casting – highly precise, used for complex and intricate shapes
Centrifugal Casting – used for pipes and rings by spinning the mould

Applications:

Casting is widely used in industries like automotive, aerospace, construction, and art to produce parts like engine blocks, turbine blades, and sculptures.