Chapter 8. Manufacturing and Fabrication
Basic processes [14]:
| Process | Description | Examples |
| Casting | Pouring molten material into a mould | Engine blocks, metal fittings |
| Forming | Shaping by force without removing material | Forging, bending, rolling |
| Machining | Removing material with cutting tools | Turning (lathe), milling, drilling, grinding |
| Joining | Connecting parts | Welding, brazing, soldering, riveting, bolting, adhesives |
| Additive manufacturing | Building up layer by layer | 3D printing |
Machining basics. A lathe turns a workpiece against a cutting tool; a milling machine moves a rotating cutter across the work; a drill press cuts holes. Use correct cutting speeds, coolants, guards and clamping, and never wear loose clothing or jewellery near rotating machines [8][14].
Welding and joining. Common processes include shielded metal arc (stick), MIG/MAG (gas metal arc), TIG (gas tungsten arc) and oxy-fuel. Welding needs protective helmets and clothing, good ventilation to remove fumes, and control of fire hazards. Soldering joins electronic components; brazing uses a filler metal with a lower melting point than the base metals [14].
CNC (computer numerical control). Machines follow programmed instructions (often G-code) to produce parts accurately and repeatedly.
3D printing. Builds objects by adding material layer by layer from a digital model, useful for prototypes and custom parts [15].
Woodworking basics. Measure and mark, saw to the line, plane and sand surfaces, assemble with joints, glue, nails or screws, and finish with sealers, varnish or paint.
Finishing: deburring, grinding, polishing, painting, plating and powder coating.
Inspection. Check dimensions and appearance against the drawing and tolerance.
Review: Name two ways to join metal parts permanently. (Answer: for example, welding and riveting.)