Different Types of Manufacturing Processes You Need to Know!

The term 'manufacturing' typically brings to mind pictures of never-ending assembly lines, greasy overalls, and even grittier mechanics creating some metallic contraption.

This may have been true in the early 1900s, but there are now many different manufacturing options. Even the most seasoned manufacturer could be surprised by some manufacturing kinds. With the industrial revolution, the industry has become significantly more diverse.

Manufacturing processes are essential to any business that makes products. But, with so many different manufacturing processes available, it can be difficult to understand which process is best for a product or a project. In this blog, we’ll take a closer look at the various manufacturing processes and what makes each unique! 

What is Manufacturing?

Manufacturing is the process of creating a product and involves everything from handcrafted products to large-scale, fast-paced manufacturing. When most people think of manufacturing, they picture a factory with assembly lines and workers in hard hats. But there are many different types of manufacturing, each with its unique process. 

Primary Manufacturing

Primary manufacturing is the process of creating a product from raw materials. This can be done through machining, casting, forging, or other processes. Primary manufacturing is often used to create metal parts or products.

Secondary Manufacturing

Secondary manufacturing refers to manufacturing primary products and further processing them into finished goods. This can be done through assembly, packaging, or other methods. Secondary manufacturing is often used to create consumer products such as electronics or appliances.

Types of Manufacturing Processes

There are several manufacturing processes, each with advantages and disadvantages. The most common types are as follows.

• Mass production is the most efficient manufacturing process, as it relies on large-scale production to keep costs down.
• Assembly-line production is the second most common manufacturing process and is used when products need to be assembled from individual parts. 
• Lean manufacturing is a more efficient version of assembly line production that seeks to eliminate waste in the manufacturing process.
• Just-in-time manufacturing is a process that minimises inventory by only producing what is needed when needed.

Popular manufacturing processes

Below are some of the most important manufacturing processes required to convert a raw material into a finished good.

• Casting
• Lathing
• Milling
• Welding
• Forging
• Machining

Casting

Casting is a manufacturing process in which the raw material is melted and poured into a mold to create the desired shape. The material is then cooled and removed from the mold. Casting can create objects of all shapes and sizes and is often used for metal objects such as engine parts or jewellery.

There are two main types of casting:

1. Hot casting - involves melting the material at a high temperature before pouring it into the mold. This method is often used for metals such as steel or aluminium. 
2. Cold casting - involves mixing the material with a liquid polymer to create a putty-like substance that can be poured into the mold. This method is often used for plastics or resins.

Lathing

Lathing is a machining process in which parts are produced by rotating a workpiece against a cutting tool. This process can produce cylindrical, conical, or spherical shapes. It is commonly used to produce shafts, bushings, and engine parts.

Milling

Milling is a manufacturing process using a rotary cutting tool to remove material from a workpiece. The milling process can be used to create various parts and products, and it is often used in conjunction with other manufacturing processes, such as machining and turning.

Welding

Welding is a process that joins two materials, usually metals or thermoplastics, by using high heat to melt the materials and create a joint. There are many different types of welding, but the most common are as follows.

• Arc welding
• Oxy-fuel welding
• Laser welding.

Arc welding

Arc welding is the most common type of welding, and it uses an electric arc to create the heat needed to melt the metal. The workpiece is kept, and an electric arc is created at a very high temperature in a very small space. The electrode can be either consumable (meaning it melts during the process and becomes a part of the weld pool) or non-consumable (meaning it does not melt).

Oxy-fuel welding

Oxy-fuel welding is a type of welding that uses oxygen and fuel gas to generate the heat needed to weld. The most common fuel gases used in oxy-fuel welding are as follows.

• Propane
• Acetylene
• Hydrogen.

Laser welding

Laser welding is a type of welding that uses a laser beam to create the heat needed to weld. Laser beams can be focused very tightly, so laser welds can be precise. Laser welding operates in two different modes: conduction-limited welding and keyhole welding. The mode in which the laser beam will interact with the material it is welding will depend on the power density across the beam hitting the workpiece.

Forging

The process of forging involves using high temperatures and pressures to shape metal into the desired shape. Forging can be performed using a variety of different methods, including, but not limited to,

• Hammering
• Pressing
• Rolling.

Forging is often used to create parts that are stronger than those that can be created through other manufacturing processes. This is because the forged metal undergoes plastic deformation during the forging process. This deformation makes a material much more resistant to fracture than a material undergoing other manufacturing processes.

In addition to being strong, forged parts are typically more resistant to wear and tear than parts created through other manufacturing processes. Forged metals also tend to have better resistance to fatigue than other metals.

Machining

Machining is a metal manufacturing method typically used to create parts with high precision and detail. Machining is a manufacturing process that involves,

• Cutting
• Shaping
• Drilling

CNC machining is a type of machining that uses computer-controlled machinery to produce parts with a high degree of accuracy. CNC machining is typically used for small to medium production runs.

Wire EDM is another type of machining that uses electrical discharges to cut metal components. Wire EDM is typically used for production runs of any size.

Other factors to keep in mind! 

There are three main factors that you have to keep in mind when choosing a process to manufacture a desired product.

• Batch production
• Mass production
• Continuous production

Batch production

Batch production is a manufacturing process where products are made in small batches. This is often used for products made to order or when there is limited demand.

The advantage of batch production is that it allows companies to be flexible with their production. They can change the design or process without retooling their entire operation.

The disadvantage of batch production is that it can be costly and time-consuming if the batches are not well-planned.

Mass production

Mass production is a manufacturing process where products are made in large quantities. This is often used for products with a high demand that needs to be produced quickly and cheaply.

The advantage of mass production is that it allows companies to produce a lot of products in a short amount of time.

The disadvantage of mass production is that it can be inflexible; if changes need to be made, the whole operation needs to be retooled.

Continuous production

Continuous production is a manufacturing process where products are produced continuously without stopping.

Conclusion

We hope this article has shed some light on all of these factors so that you can best determine which type of manufacturing process is suitable for your project.

As the world of manufacturing becomes increasingly complex, students and professionals alike need to have a clear understanding of the different types of manufacturing processes. Here's where Skill-Lync comes in. Skill-Lync offers courses for students and professionals to upskill themselves, from traditional machining and casting to newer technologies like 3D printing and additive manufacturing.