Common Precision Manufacturing Ways For Consumer Goods

Accuracy and precision drive the manufacturing sector. They serve as the backbone of quality and ensure that parts and components meet and exceed modern customer’s expectations. Consumer goods must be manufactured exactly to specifications for safety reasons and optimal performance. Precise manufacturing also helps to improve product appeal and your brand’s reputation.

There are many manufacturing techniques available for consumer goods. However, not all will meet the standards and requirements. This article will cover the common precision manufacturing techniques for consumer goods. It will explain how these processes work, their peculiarities, and how they differ from one another. Let’s get started 

What is Precision Manufacturing

Precision parts manufacturing is different from regular manufacturing that you know. It involves the use of modern techniques and processes to produce parts with high accuracy and extremely tight tolerances. Precision manufacturing is important when fabricating parts that need to be arranged together to make a whole. When you don’t manufacture such parts with tight tolerances, they may not connect properly. 

It is also important when adding complex features that are important for functionality on a part. The parts may be useless if there are slight deviations. However, you should not always specify tight tolerances. Avoid tight tolerance requirements when functional requirements are not critical or aesthetics is not a priority. This is because machining with high accuracy is time-intensive and costly. 

Common Precision Manufacturing Techniques for Consumer Goods

There are different techniques you can use for precision manufacturing in consumer goods. The following are the most common

CNC Machining

CNC precision machining is a subtractive manufacturing technique that uses programming languages to control the movement of complex tools and machinery. These tools remove excess material gradually from stock to produce the final part with a tolerance level as low as +/- 0.001 inches. 

To carry out precision CNC machining, you start with the creation of a 2D or 3D model of the final design using CAD software. You then convert the model to a language the machine understands in the form of G-code and M-code. The final step involves configuring the machine and executing the operation. 

CNC precision machining is compatible with metals, plastics, composites, wood, and foam. There are different types of precision CNC machining operations you can use for consumer goods. They include;

CNC Milling

CNC milling describes the process of using a cutting tool mounted on a rotating spindle to shape a stationary workpiece. The machine can move along different axes to produce a tolerance between +/- 0.001 to +/- 0.005 inches. Precision CNC milling is important with working on plane and flat surfaces. It is cost-effective for rapid prototyping and small-batch production. 

CNC Turning

In CNC turning, the workpiece rotates over a stationary cutting tool to craft parts and components. There are different operations you can carry out with precision CNC turning with the most common being taper turning, facing, and grooving. CNC turning process machine parts exactly to specification with a standard tolerance of +/- 0.005 inches. 

CNC Drilling

CNC drilling involves the use of drill bits to create holes that serve functional or aesthetic purposes. You can use the holes with screws and bolts during part assembly and joining. Note that the size of the hole depends on the type of drill bits you are using. This process is suitable for manufacturing phone accessories, game consoles, and cosmetic packaging. 

Sheet Metal Fabrication

Sheet metal fabrication is the process of transforming sheets of metal into useful products and components. In sheet metal fabrication, you use various techniques and operations to manipulate metal sheets and turn them into various shapes and designs. There are many metals suitable for this process. It is easy to shape aluminum, stainless steel, brass, and copper of thickness ranging from 0.006 to 0.25 inches. Sheet metal fabrication techniques come under 3 categories; cutting, forming, and joining.

Cutting Sheet Metal

Cutting is usually the first step in sheet metal fabrication. You can use it alone or in combination with others. Cutting can either be with shearing or without shearing. Examples of cutting with shear force include sawing, punching, and blanking. Laser cutting, water jet cutting, and plasma cutting uses heat and pressure to cut through. 

Forming Sheet Metal 

Forming techniques shape a metal workpiece without removing or adding extra material. Forming entails rolling metal sheets to reduce thickness level and bending to the desired angle. It can also involve hemming, stamping, and curling the tip of metal sheets to conceal burrs and make them safer to handle. 

Joining Sheet Metal

You can also join sheets of metals together using various means. Welding and riveting are the two main techniques that come under joining. Welding uses heat to join two or more parts together. This technique creates a strong and permanent joint. You can also use different types of rivets to fasten metal sheets. Riveting can be carried out at room temperature or with the application of heat. 

Injection Molding

Injection molding is another precision manufacturing method you can use when producing plastic consumer goods. This process is suitable for the mass production of complex-shaped parts. To carry out precision injection molding, you first design and create a mold using suitable techniques. Note that the mold can have a single or multiple cavity depending on what you want.

After creating the mold, set up the injection molding machine and choose the appropriate plastic material. You then feed the plastic granules into the hopper carefully. Inside the barrel, the plastic melts and it is injected under pressure into the mold cavity. After filling in the cavity, you then allow the molten material to cool and solidify. Finally, eject the part and inspect for flaws.

Precision injection molding is a cost-effective process as you can reuse the mold. This technique allows for easy scalability and enables you to achieve design versatility.  However, it has a long lead time and comes with some environmental concerns. You can use this process when manufacturing handles, window holders, and racks. 

Casting

Casting describes the process of pouring molten metal and plastic into a mold that contains a negative impression of the final shape. As the material cools and solidifies, it takes the shape of the mold producing a strong and high-quality part. Note that casting is different from injection molding. In casting, the mold fills under the gravity force while injection molding uses pressure to carry out the operation. There are different types of casting you can use for precision manufacturing. The most popular ones are;

Sand Casting

In this process, you use sand joined together with a binder and water to make the mold. Sand casting is a low-technology technique suitable for producing large metal parts with high accuracy and precision. However, the mold is not reusable as you have to break it apart to extract the final casting. 

Die Casting 

Die casting is different from other types. Here, the molten metal fills a steel die under pressure. The amount of pressure you use depends on the specific die-casting process. The pressure in low-pressure die casting is around 2 to 15 psi. However, that of high-pressure die casting can be as high as 20,000 psi. 

Investment Casting

Investment casting, also known as the lost wax process, uses a wax pattern and refractory material to create a product. Investment casting is accurate and ensures repeatability and consistency in quality. It results in low material wastage and requires less post-processing. 

3D Printing

3D printing is an additive manufacturing technique you can use to make three-dimensional precision manufacturing components from a digital file. 3D printing is mainly for plastic and resins. However, it is also ideal for metal and alloys. Some examples of 3D-printed products include footwear, eyewear, and phone accessories. There are several types of 3D printing techniques which include

Stereolithography (SLA)

SLA uses a high-powered laser to solidify photosensitive liquid resin layer by layer to create a part. SLA is ideal for components that have fine details and require a smooth surface finish. It is versatile and supports a wide range of materials. 

Selective Laser Sintering (SLS)

You also employ a laser beam to carry out SLS. However, the starting material is powdered particles that are sintered in layers to produce a solid component. The laser step in SLS involves removing the final part from the bed and cleaning it. SLS is accurate and the parts do not need support structures. 

Fused Deposition Modeling (FDM)

FDM is different from the types previously described. Here, you feed the plastic filament into the extruder and melt it. The heated nozzle moves back and forth depositing the material in layers to trace the pattern. FDM is fast and comes with a lost cost. The final parts are dimensionally accurate with a good surface finish. 

Conclusion

Precision manufacturing is important when producing high-quality consumer goods and products. By using appropriate techniques, you will ensure reliability and remain relevant in the market. Choosing the right precision manufacturing way depends on many factors. You have to consider the part’s complexity, material properties, production volume, and the required lead time. Note that precision manufacturing is not limited to consumer goods. You can also use it for rapid tooling and custom part manufacturing.