Processes
Manufacturing Processes We Match
Picking the process is half the price. This page shows what each one is good for, what tooling it needs and what a manufacturer wants to see before quoting.
Eight processes side by side
| Process | Best for | Tooling | Typical order size |
|---|---|---|---|
| CNC machining | Metal and plastic parts with tight tolerances, from one-off prototypes to a few thousand pieces. | No hard tooling. Fixtures only. | 1 to 5,000 per order is typical |
| Sheet metal fabrication | Enclosures, brackets, panels and frames cut, bent and welded from sheet. | Usually none. Laser or punch programs and standard press brake tools. | 10 to 10,000 per order is typical |
| Injection molding | Plastic parts needed in the thousands with the same shape every time. | A steel or aluminum mold, paid once before production. | From about 1,000 per order upward |
| Die casting | Aluminum or zinc housings and structural parts with thin walls at volume. | A steel die, paid once. Machining fixtures for the critical faces. | From about 1,000 per order upward |
| Metal stamping | Flat or formed sheet parts in high volume: clips, terminals, shields, brackets. | A progressive or stage die, paid once. | From about 5,000 per order upward |
| Aluminum extrusion | Long parts with a constant cross-section: heat sinks, rails, frames, housings. | An extrusion die, low cost compared with a mold. | Usually sold by weight, with a minimum run per profile |
| Welding and fabrication | Frames, bases, tanks and structures built from plate, tube and section. | Welding jigs for repeat orders. | 1 to a few hundred per order is typical |
| Assembly and box build | Finished sub-assemblies or products built from made and bought parts, tested and packed. | Assembly fixtures and test jigs. | Depends on the product |
Order sizes are typical ranges, not limits. A manufacturer will tell you where your part sits.
What to send for each process
CNC machining
STEP model plus a PDF drawing with tolerances, material and finish.
Sheet metal fabrication
Flat pattern or 3D model, sheet thickness, material grade, finish and hardware list.
Injection molding
3D model, resin grade or required properties, color, texture and yearly volume.
Die casting
3D model, alloy, which faces get machined, finish and yearly volume.
Metal stamping
Part drawing, material and temper, thickness, plating and yearly volume.
Aluminum extrusion
Profile drawing, alloy and temper, cut length, machining and anodizing needs.
Welding and fabrication
Assembly drawing with weld symbols, material grades, coating and inspection needs.
Assembly and box build
Bill of materials, assembly drawing or work instruction, test and packing requirements.
One product, several processes
Few products are made by one process. Here is how a typical handheld device splits. You send the whole product once and we route each part.
| Part | Process |
|---|---|
| Outer housing | Die casting, then CNC machining of the sealing faces |
| Top cover | Injection molding |
| Mounting bracket | Sheet metal fabrication or stamping, by volume |
| Shaft and bushings | CNC turning |
| Heat sink | Aluminum extrusion, cut and drilled |
| Finished unit | Assembly, functional test and packing |
Illustrative example.
Not sure which process fits?
Send the drawings and tick "Not sure" on the form. Volume usually decides it. A housing that is machined at 50 pieces is often die cast at 5,000, and the matched manufacturer will say where the switch pays off.