Technologies

What manufacturing processes exist, and when are they economically viable? This category explains essential industrial technologies—from traditional machining to innovative processes like additive manufacturing. Perfect for buyers who want to understand technical backgrounds.

• Additive manufac­turing

  The additive manufacturing term refers to all , in which material layer is applied to a three-dimensional component for layer. The forming method has its strengths, especially in highly complex structures, and enables the user to have a high degree of design freedom and functional optimization. To date, additive manufacturing has been used predominantly in prototype construction and in the production of small batch sizes. Meanwhile, however, the technology is increasingly moving into series production, as it enables the strong individualization of products and gives the user the opportunity to differentiate themselves on the market.

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• Automation engineering

  The field of automation technology deals with the improvement of the degree of automation of machines and systems. The primary aim of all measures of automation technology is to relieve the human being from strenuous, time-consuming and dangerous work. The associated cost reductions and quality improvements are further reasons for greater automation in industry. The aim is achieved primarily by signal acquisition independent of humans and requires extensive knowledge of the fields of mechatronics, electrical engineering, control technology, robotics and information technology.

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• Component assembly

  The concept of assembly assembly refers to the professional assembly of individual assemblies or components into a finished product. The assembly assembly is often carried out in industry on optimized assembly lines in order to realize time and cost advantages. The assembly is a very wide-ranging term that is used across the industry for a variety of assembly steps. The is applied both in the small and large series, depending on the complexity of the modules. The positioning of the assembly assembly in the production process is very flexible. The assembly can be used as an earlier intermediate step or can also represent the last step for the finished end product. In industry, assembly assembly is often carried out in wage production to rely on the expertise of specialized assembly experts.

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• Blow moulds

  The blow molding is a process for producing hollow bodies from thermoplastics. In this case, a preform is subjected to internal pressure and thereby pressed against the contours of a blowing tool, whereby it assumes the desired shape. The blow molding is one of the special methods of injection molding and has gained great importance in the production of bottles, containers and other plastic hollow bodies in the plastics processing industry. The method is distinguished in particular by the fact that the manufactured parts have comparatively small wall thicknesses. As a result, the material expenditure is low and the costs are kept low.

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• Sheet metal processing

  The sheet metalworking includes various for manufacturing custom sheet metal products. The starting material of the sheet metal processing is a sheet metal sheet or coarse sheet metal, which is brought into the desired shape and the desired design by cutting, forming, joining and finishing in various processing steps. Due to the multiplicity of different functions and applications, different methods for sheet metal processing are used in the metal processing industry. The most common methods include welding, cutting, bending, punching, shaping, rolling and joining.

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• Blacking

  Brunning is a surface process for producing a black protective layer on iron-containing surfaces. The aim of the bronification is primarily to protect against corrosion, whereby a decorative, antique appearance is frequently also achieved. The Breasting is defined in the standard DIN 50983 and is usually based on the immersion of the workpiece to be treated into an acidic or alkaline solution, the broaching agent. This process forms a black mixed oxide layer on the surface of the workpiece, which is also referred to as “stainless grate”. Black-oxideating is therefore not a coating, but a conversion of material.

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• Cloud manufacturing

  Cloud Manufacturing describes a modern production concept. The production factors, capacities and techniques are linked with cloud manufacturing and transformed into a holistic supply of manufacturing services. The advantage: The entire manufacturing process can be managed and operated intelligently and uniformly. The aim is a complete and therefore economic utilization of all the machines involved in the manufacturing process, as well as a joint use of all the persons and companies involved. Cloud manufacturing is intended for the entire production: from design phase to production to maintenance. Machines, competencies and software packages are offered as “Manufacturing as a Service” – so-called MaaS. Based on CAD data and knowledge-based machine and material databases, the optimal services are determined, capacity planning is carried out and orders are planned and controlled.

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• CNC turning

  For CNC it is an automated for the production of rotationally symmetrical components. The process offers far-reaching advantages over conventional production on a rotary bench and is predominantly used in the metal processing industry. CNC lathe is characterized by a high degree of automation and convinces above all by a high repeatability as well as the possibility to efficiently manufacture even complex rotationally symmetrical geometries. The range of applications of CNC lathes is diverse and ranges from the production of CNC lathes for the automotive industry and machine and plant construction to the production of small parts for medical technology and electrical engineering. Both small and medium series and large series can be manufactured economically by CNC machining.

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• CNC milling

  The CNC milling is one of the cutting and is based on the use of automated CNC machine tools that produce workpieces with high precision using modern control technology. Milling with CNC machine tools is nowadays used primarily in the metal processing industry and allows users to manufacture inexpensive workpieces with the highest demands of accuracy and complexity. CNC milling machines are able to realize cutting speeds of up to 10,000 revolutions per minute and thereby achieve economic advantages in particular in series production. The CNC milling is not limited to metal processing, but is also used in plastic and wood processing.

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• Wire bending

  The wire bending is one of the transforming and is used in the metalworking industry for the production of wire bending parts for machine and plant construction, the electrical industry and many other industries. According to the standard DIN 8580, the wire bending of the group of bending deformation is to be attributed. The method can in principle be applied to all metallic wires and is nowadays frequently taken over by automated CNC machines. The product spectrum is diverse and ranges from wire spirals to wire handles and springs to welded wire bending parts.

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• Turning

  The turning is one of the most important cutting methods and is used to manufacture cylindrical components. A single-edged tool (e.g. a rotary chisel made of high-speed steel) is guided to a rotating component in order to remove successive chips and to achieve the desired geometric shape.

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• Surface hardening

  The use hardness refers to a thermochemical process in which the mechanical properties of the edge layer of metallic components are improved in a targeted manner. In this case, the surface is first carbonized, then hardened and then let on. The use hardening is carried out in the hardening process and allows the user to impart a significantly higher surface hardness to the edge layer of the workpiece. Use-hardened components are distinguished by a correspondingly high wear resistance with increased bending fatigue strength and are thus particularly predestined for use in transmission technology.

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• Anodizing

  The anodizing is a process for surface treatment of aluminum. By means of anodic oxidation, a protective layer can be produced on the metal, which prevents the natural, uncontrolled oxidation of the metal by reaction with oxygen from the ambient air. The special feature of the method is that, unlike for example in, no layer is applied, but a conversion of the uppermost aluminum layer takes place. This layer serves not only for corrosion protection, it can also be colored by means of an additional process step. Resistance and optics of the anodized layer can be influenced by the suitable choice of the process parameters.

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• Deburring

  In industry, deburring refers to processes for removing edges, splitters and fiber-optic elements on workpieces – the so-called ridges. The method serves on the one hand to ensure the operability of machine elements and on the other hand to reduce the risk of injury. Processes of deburring are predominantly used in the metal and wood processing industry, but are also used in the production of plastic parts. Depending on the shape, material and dimension of the component, different methods are used for removing the burr.

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• Extrusion

  The extrusion is a forming process which is mainly used for thermoplastics. The plastic is pressed through a shaping opening as a viscous mass under high pressure and high temperature. Extrusion is one of the most widely used processes in the plastics processing industry and, thanks to its wide range of advantages in terms of efficiency, has gained great importance in the production of plastic parts. An extruder is used for extrusion, which is also referred to as a screw press. In principle, a distinction is made between the single-screw extruder and the twin-screw extruder.

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• Manufacturing process

  All processes for the production of geometrically determined bodies with predetermined technical properties and dimensions are referred to as manufacturing processes. In addition, material-changing methods such as hardening or soft annealing also belong to the manufacturing processes. Under the preamble of manufacturing methods, the individual methods are divided into six main groups according to their common features. These are described in more detail in DIN 8580 and categorized in subgroups and process variants. Manufacturing processes serve both for the production of semifinished products for further processing and for the production of final products.

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• Milling

  Milling refers to a cutting which is used for manufacturing components with a specific geometric contour. Thanks to its high efficiency, productivity and precision, milling is particularly popular in metal-processing production technology. The milling can be used both for the processing of planar surfaces and for the production of complex, three-dimensional contours. A milling tool with geometrically determined cutting edges is used and, during the milling process, material is removed from a workpiece by a rotating circular movement. Milling can now be carried out both manually and using state-of-the-art CNC machine tools with a high degree of automation.

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• Electroplating

  The electroplating (also electroplating) is a process from surface and layer technology for electrochemical deposition of metals on metallic or metallized surfaces using an electrolyte and direct current. The galvanic coating usually serves to protect the workpieces from corrosion or to increase the wear resistance of their surface. The method is particularly often used for coating steels with metals of a suitable property profile. Such metallic coatings have a wide field of application since they obtain the metallic appearance of the workpieces and the electrical conductivity.

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• Drop forging

  The forging is part of the group of forming methods. In industry, it is mainly used for the automated production of metal components that are subject to dynamic loads. The use of at least two shaping tools, or sinks, which move relative to one another is characteristic of the method. Forming by means of sinks is the most widely used forging method in industrial practice. The method is distinguished by the good material utilization, the die forging parts by the advantageous ratio between weight and strength. From the likewise widespread free-form forgings, the method is distinguished by the superior dimension accuracy.

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• Plastic injection molding

  In the case of plastic injection molding, molten plastic is injected into the shaping cavity (cavity) of a tool, compressed under pressure, cross-linked or brought to cooling and then ejected as a molded part. The injection molding is the most used method for the highly automated production of workpieces from plastic by the processing of powder or granules. Complexly shaped workpieces can be produced in almost any size. The high accuracy and short cycle times predestine the method for economical series production.

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• Laser engraving

  The laser engraving is a method of surface treatment using a high-energy laser beam for marking, marking or decoration of objects. The contactless method is characterized by high automation, durability and flexibility. The laser marking scores through versatile applications and is therefore very popular across the industry. engravings can be applied to many different materials and prove to be particularly durable and durable. Typical application areas are, for example, the production of type plates or the numbering of individual parts in series production.

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• Laser cutting

  The laser cutting is part of the group of separating and is based on the separation of solid bodies by laser radiation. The method allows the user to cut complex contours from almost all conceivable materials. The use of continuous or pulsed laser radiation for cutting or cutting workpieces has far-reaching advantages compared to other methods. In the metal processing industry, laser cutting is particularly popular due to the high precision, efficiency and productivity. The combination of laser technology with highly automated CNC technology also ensures a high cost-effectiveness even with small batch sizes.

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• Laser cutting metal

  Metal is one of the separating, thermal . By using the laser beam, solid bodies of metal are cut through. The separation is effected by the strong heating which the laser beam reaches by focusing on the corresponding point on the surface of the workpiece: the material completely melts or evaporates. After penetration of the material, the actual cutting process begins. Laser cutting of metal is one of the most flexible, precise and most economical separating . Typical applications can be found wherever a complex design needs to be processed quickly and as free of force as possible.

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• Laser beam welding

  The laser welding is one of the following and is used in the industry to connect metallic components and thermoplastics. The method is based on the punctual energy supply via a laser beam, wherein usually no additional material is used. Thanks to the energy-intensive laser beam, laser welding is characterized by a very high welding speed, a low thermal distortion in the component and a narrow and precise welding seam. It is therefore used in high-precision applications in , in the automotive industry, in steel construction, in shipbuilding, in aerospace and in other industries.

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• MAG welding

  The MAG welding is part of the group of gas-protected metal arc welding processes, in which a wire electrode is melted under protective gas, and is widely used in industrial production for joining metallic materials. In the case of MAG welding, the permanent connection of metals is achieved using strong heat and welding aids. The heat input for the melting welding process causes an electric arc. The inserted wire electrode flows together with the melted base material as a welding additive and contributes to the formation of the weld seam. The method is distinguished by a high processing speed and the possibility of automation. It is therefore particularly suitable for industrial applications.

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• Metal construction

  Metal construction – former construction locksmith – refers to the processing of metals and their connection with other materials in industry and crafts. The greatest importance in metal construction is the processing of steel, both as hot-rolled construction steel and as non-rusting steel. The processing of aluminium is strongly represented in the window, facade and terrain construction. Metal construction in combination with plastics and glass is often part of constructional constructions such as window construction, winter gardens and railing systems.

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• Plasma fusion cutting

  The plasma cutting is one of the thermal separation methods and allows the user to precisely cut sheets. The widespread method uses the thermal and kinetic energy of a plasma gas stream for liquefying and blowing out the material. The plasma cutting is used, in particular, when the material cannot be severed or only partially by conventional combustion cutting. The typical areas of application include cutting sheets of high-alloy steel, aluminium or copper. The method is distinguished by high cutting speeds, post-processing cuts, low heat input and low investment costs.

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• Powder coating

  The powder coating is a coating process for conductive or conductive materials. In the process used above all for steel and aluminum, a powder coating is applied to the pretreated surface and subsequently crosslinked under the action of heat. The powder coating protects the substrate from corrosion and scratches. In addition, the method of surface technology is used to influence the optical and functional properties of workpieces. Powder-coated products can be found in the following areas: Doors and windows Facade construction Machine and vehicle components Household nurses (white goods)

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• Spot welding

  The spot welding is also referred to as resistance spot welding and is one of the welding methods without using protective gas. The method is based on the punctual heating and liquefaction of two workpieces pressed on one another by applying a strong voltage. Compared to other welding processes, spot welding is characterized by good productivity, a high degree of automation and a low material distortion. For this reason, the joining method is used primarily in bodywork and vehicle construction, in sheet metal processing and in the electrical industry.

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• Friction stir welding

  The friction welding (see: Friction Stir Welding) belongs to the group of friction welding processes and is particularly suitable for joining non-ferrous metals with low melting temperature and mixed compounds. The method is based on the use of a rotating pin which is guided between the contact surfaces of two workpieces. The friction heat produced thereby ensures a plasticization of the material and allows welding of the workpieces. Stir friction welding produces particularly high-quality welded joints with excellent fatigue properties and is therefore very popular in the metal processing industry.

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• Sand blasting

  The sandblasting is one of the processes of surface treatment and is mainly used for removing rust, soiling, colour residues and other impurities. In the method, a blasting agent is thrown at high speed onto the surface to be treated. Sandblasting enjoys great popularity in the metalworking industry and in construction. On the one hand, the method can be used for efficient removal of impurities and for the preparation of surfaces, but on the other hand also serves for the production of optical effects such as, for example, the matting of glass or stone surfaces.

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• Punching

  Stamping is a separation process for the production of flat parts from various materials such as sheet metal, cardboard and textiles with a punch press or by punching with a hammer head on a cutting tool. Stamping is mainly used to hole flat materials. The minimum equipment of a punching device consists of two tool parts: a holder for punches and a holder for dies. When the punch is inserted into the die, the material is separated by a shear cut.

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• Bar extrusion

  The extrusion is one of the pressure-forming and is used to manufacture metallic profiles with different geometries. The process is used in the metal processing industry and in the construction industry, inter alia, for the production of hollow profiles. The extrusion allows the user to produce metallic profiles also with complex shapes such as irregular prismatic profiles. The technology is distinguished in particular by a high cost-effectiveness compared to alternative methods at low unit numbers. The extrusion is mainly used for aluminum components, but also for other materials.

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• Deep drawing

  We are the most important manufacturing technology in sheet metal forming. It can be used both for large series and for small series. Deep drawing with different metallic materials is also possible. Sheets that can be used in deep drawing include construction steel, stainless steel and aluminum, but also copper, titanium and brass. Deep-drawing is also possible for plastics, the technology being used here thermoforming. Deep drawing with tools The most typical variant of deep drawing is deep drawing with rigid tools from . These tools consist of a die, a die and a sheet metal holder or Holder. The cut sheet is fixed by the sheet metal holder. During the deep-drawing process, the punch presses the sheet over the die radius and presses it into the die, also called a drawing ring. The edges of sheet metal and stamps are rounded to prevent the sheet metal from tearing during forming. The change in the initial form is stronger in deep drawing than in most other forming methods. The finished product takes a completely new shape and hardly remembers the original workpiece. With correct application and the corresponding requirements, deep drawing is an extremely efficient, fast and proven method which is suitable for producing large quantities of uniform products. Deep-drawn parts are manufactured especially for the automotive industry, but there is also a need for deep-drawn parts in the gastronomy, the sanitary sector and the aircraft construction industry.

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• Trowalizing

  The trolling is also referred to as sliding grinding or sliding cutting and is a separating method of surface machining. In this case, metal workpieces together with a grinding means are usually introduced into a rotating drum in order to remove material in a targeted manner. Trowalization is described in the DIN 8589 standard, together with the lapping and polishing, and is referred to as sliding panels. The process is very popular in the metal processing industry, as it can perform several tasks from and rounding over smoothing and polishing to matting and grinding. The desired result of the surface treatment can be brought about in a targeted manner by the variation of the machines and grinding means used.

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• Water jet cutting

  The water jet cutting is a separate , where water is used under high pressure to cut through various materials. The water jet cutting is regarded as a particularly environmentally friendly, economical and material-friendly separation process. Depending on the material to be separated, pure water or water with an abrasive addition is optionally used in water jet cutting. While pure water is suitable for cutting soft materials such as plastics, foams, films and paper, an abrasive water jet is required for separating steel, ceramics or glass. The water jet cutting has proven itself primarily in the cutting of composites and is applied across the industry due to its extensive advantages.

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• TIG welding

  The tungsten inert gas welding (IG welding) belongs to the group of melt welding processes and is characterized by particularly clean processing, high seam qualities and almost universal applicability in the metal sector. Due to the particularly precise tuning of the welding current to the respective welding task, the welding method is particularly suitable for root positions and forced positions. For this reason, WIG welding enjoys great popularity in tasks with high standards of precision and seam quality, such as pipeline and apparatus construction, power plant construction and chemical industry.

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• Machining

  The preamble of machining includes a series of , which are characterized by the machining of workpieces for producing a desired shape.

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