When looking for a contract manufacturer for metal parts, it is crucial to understand the different metal fabrication processes, such as casting, forging, machining, and stamping, as well as the types of parts or components each method produces. Each process has specific applications, ranging from precision parts used in electronics to high-strength components in the automotive and aerospace industries.
In this blog, you will explore the key differences between these methods and their practical applications, helping you choose the most suitable contract manufacturer for your specific metal part needs.
Types of Metal Fabrication Processes
Casting
Casting involves pouring molten metal into a mold to create parts with complex shapes. This method is beneficial for producing intricate designs that would be difficult or expensive to manufacture through other processes.
Examples of parts: Engine blocks, transmission housings, turbine blades, and pump casings are commonly produced through casting. The automotive and aerospace industries often use casting for components that require detailed geometries.
Forging
Forging shapes metal using compressive forces, usually with a hammer or press, resulting in parts with enhanced strength due to the alignment of the metal’s grain structure. This process is ideal for high-strength, wear-resistant parts.
Examples of parts: Crankshafts, connecting rods, wrenches, gears, and fasteners such as bolts are often forged. Forging is popular in the automotive, aerospace, and tool manufacturing sectors for parts that must withstand high stress.
Stamping
Stamping presses metal sheets into specific shapes using dies, making it a fast, cost-effective method for producing large parts.
Examples of parts: Stamping is commonly used for producing brackets, clips, metal enclosures, and automotive body panels. High-volume industries like automotive and appliance manufacturing rely heavily on metal stamping to create consistent, mass-produced parts.
Machining
Machining removes material from a metal workpiece to achieve the desired shape, using tools such as lathes, mills, and drills. It is highly precise and ideal for creating parts with tight tolerances.
Examples of parts: Machining is used to create precision parts like medical implants, custom fittings, aerospace components, and electronic housings. Industries such as aerospace, medical, and defense heavily use machining for components that require high accuracy and complex features.
Welding
Welding joins metal parts by melting and fusing them together, creating strong bonds in structures or assemblies. This method is commonly used in both large-scale construction and small-component manufacturing.
Examples of parts: Steel beams in construction, pipelines, automotive frames, and ship hulls are often welded. In smaller applications, welded parts might include bike frames, structural supports, and metal furniture.
Extrusion
Extrusion pushes metal through a die to create long shapes with a consistent cross-section, such as tubes, rods, or beams. This process is especially useful for materials like aluminum.
Examples of parts: Window frames, heat sinks, railings, structural supports, and piping are commonly produced through extrusion. Extrusion is often used in the construction and automotive industries for creating lightweight, durable components.
Powder Metallurgy
Powder metallurgy involves compressing and heating powdered metal to form parts, making it efficient for producing complex parts with unique material properties.
Examples of parts: Gears, bearings, filters, and cutting tools are typically made using powder metallurgy. This process is widely used in the automotive, aerospace, and electronics industries, especially for parts that require intricate shapes and high precision.
Additive Manufacturing (3D Printing)
Additive manufacturing builds parts layer by layer from metal powder or wire, making it possible to create highly complex, custom parts with minimal material waste.
Examples of parts: 3D printing is increasingly used to produce custom medical implants, turbine blades, lightweight aerospace components, and automotive prototypes. The aerospace, medical, and prototyping sectors benefit from the design flexibility and speed of additive manufacturing.
How Much Do Metal Contract Manufactured Parts Cost?
When choosing a metal fabrication process, understanding the cost implications is crucial, as certain methods can be significantly more expensive due to factors like tooling costs, labor intensity, or material waste. Here’s a breakdown of the relative costs of each process and the reasons behind them.
Most Costly Processes
Additive Manufacturing (3D Printing)
Cost factors: Additive manufacturing is one of the most expensive processes, primarily due to the high cost of metal powders and the sophisticated equipment required. Additionally, 3D printing is often slower than other methods, especially for large production runs, which increases labor and machine time costs. However, it shines in creating custom, complex parts without the need for tooling, which can reduce costs in low-volume or prototype runs.
Why costly: Material costs, slow production speed, and expensive machinery make additive manufacturing one of the pricier options, especially for large quantities.
Machining
Cost factors: Machining can be costly due to the labor-intensive setup, the need for precision, and the significant amount of material waste generated during the process. For complex parts requiring high tolerances, machining may require multiple steps and specialized equipment, driving up both labor and material costs.
Why costly: High material waste, the need for skilled labor, and long machining times make this process expensive, particularly for parts requiring intricate features or tight tolerances.
Moderately Expensive Processes
Casting
Cost factors: Casting is moderately expensive, primarily due to the cost of creating molds, especially for more complex shapes or low-volume runs. The mold-making process involves time, precision, and the use of specialized materials like sand or steel, depending on the casting method.
Why costly: Initial mold creation can be expensive, particularly for short production runs, although high-volume casting becomes more economical over time.
Forging
Cost factors: Forging involves high equipment costs for presses and hammers, as well as significant energy consumption. Additionally, the need for skilled operators and the durability of forging dies make it more costly than simpler methods like stamping.
Why costly: High upfront equipment investment, skilled labor requirements, and energy use contribute to forging’s cost, though it provides excellent strength for parts.
Powder Metallurgy
Cost factors: Powder metallurgy requires specialized equipment and raw materials, such as metal powders, which can be expensive. While the process minimizes material waste, the high cost of raw materials and the need for controlled atmospheres or high temperatures during sintering add to the expense.
Why costly: The raw material costs and specialized equipment for compaction and sintering drive up the overall expense, although powder metallurgy becomes more economical in high-volume production.
Least Costly Processes
Stamping
Cost factors: Stamping is highly cost-effective for large production runs, as the process involves minimal material waste and can be automated for mass production. The major expense is the initial investment in dies, but once those are made, production is fast and efficient.
Why affordable: Low material waste and the ability to produce parts in high volumes make stamping one of the most cost-effective methods, especially for simple, repetitive shapes.
Extrusion
Cost factors: While the dies for extrusion can be expensive, the process itself is relatively efficient, especially for high-volume production of parts with uniform cross-sections. Material waste is minimal, and the method is straightforward once the dies are created.
Why affordable: Minimal waste, consistent part production, and relatively low labor involvement make extrusion more affordable, particularly for parts with simple shapes.
Welding
Cost factors: Welding is generally less costly for small-scale production or when parts are large and cannot be easily fabricated in one piece. However, for complex assemblies or parts requiring high precision, welding costs can rise due to labor intensity and post-processing requirements.
Why affordable: Welding is typically cost-effective for joining metal parts, although costs can increase if the process is labor-intensive or requires precision.
Conclusion
Each metal fabrication process has its own advantages and ideal applications. Whether you require the strength of forged parts, the precision of machining, or the design freedom of 3D printing, selecting the appropriate process based on the part’s design and performance needs is critical. By understanding these processes and their applications, you can make informed decisions when choosing a contract manufacturer for your metal parts.