Manufacturing Process Selection with Python (PRIMA)

1. Casting Methods

1.1 Sand Casting

What is it? The most basic casting method, using sand molds.
Main Steps: Pattern preparation → Sand mold preparation → Core placement → Casting → Solidification → Mold removal
Advantages: Suitable for large parts, low cost, applicable to various metals
Disadvantages: Rough surface, wide tolerances, labor-intensive
Applications: Machine frames, pipe flanges, large gears

1.2 Shell Moulding

What is it? Casting performed with thin sand-resin shell molds.
Main Steps: Pattern heating → Sand-resin spraying → Shell hardening → Mold assembly → Casting
Advantages: Good surface quality, narrow tolerances, minimal cores required
Disadvantages: High mold cost, not suitable for large parts
Applications: Valve bodies, gear wheels, small engine parts

1.3 Gravity Die Casting

What is it? Casting performed in metal molds using gravity.
Main Steps: Mold preparation → Mold heating → Metal pouring → Cooling → Part removal
Advantages: Good mechanical properties, repeatability
Disadvantages: High initial investment, limited to simple geometries
Applications: Automotive parts, kitchenware

1.4 Pressure Die Casting

What is it? Metal injection under high pressure.
Main Steps: Mold closing → Metal injection → Cooling → Mold opening → Part removal
Advantages: High production rate, thin-walled parts
Disadvantages: High equipment cost, internal porosity
Applications: Automotive parts, electronic housings

1.5 Centrifugal Casting

What is it? Casting performed in a rotating mold using centrifugal force.
Main Steps: Mold rotation → Metal pouring → Cooling → Part removal
Advantages: Dense structure, low porosity
Disadvantages: Only circular parts, equipment cost
Applications: Pipes, cylinders, bearings

1.6 Investment Casting

What is it? Precision casting using a wax model coated with ceramic and melted out.
Main Steps: Wax pattern creation → Ceramic coating → Wax removal → Metal casting → Mold breaking
Advantages: High precision, complex geometries
Disadvantages: High cost, long process
Applications: Turbine blades, jewelry, medical implants

1.7 Ceramic Mould Casting

What is it? Precision casting performed using ceramic slurry.
Main Steps: Pattern preparation → Ceramic coating → Drying → Casting → Mold breaking
Advantages: High temperature resistance, good surface quality
Disadvantages: Expensive, long preparation
Applications: Jet engine parts, cutting tools

1.8 Plaster Mould Casting

What is it? Precision casting using plaster molds.
Main Steps: Pattern preparation → Plaster pouring → Drying → Metal casting → Mold breaking
Advantages: Excellent surface quality
Disadvantages: Low strength, limited materials
Applications: Decorative parts, sculptures

2. Plastic Forming Methods

2.1 Injection Moulding

What is it? Injection of molten plastic into a mold.
Main Steps: Granule feeding → Plasticizing → Injection → Cooling → Part removal
Advantages: High production speed, complex parts
Disadvantages: High mold cost
Applications: Plastic caps, toys

2.2 Compression Moulding

What is it? Shaping thermoset plastics using heat and pressure.
Main Steps: Material placement → Mold closing → Compression → Cooling → Part removal
Advantages: Large parts, low equipment cost
Disadvantages: Slow production
Applications: Electrical insulators, brake pads

2.3 Vacuum Forming

What is it? Shaping heated plastic sheets using a vacuum.
Main Steps: Sheet securing → Heating → Vacuum application → Cooling → Part removal
Advantages: Low cost, rapid prototyping
Disadvantages: Limited geometries
Applications: Packaging, advertising panels

2.4 Blow Moulding

What is it? Production of hollow plastic parts.
Main Steps: Parison formation → Mold closing → Blowing → Cooling → Part removal
Advantages: Thin-walled hollow parts
Disadvantages: Mold cost
Applications: Bottles, jerrycans

2.5 Rotational Moulding

What is it? Distribution of plastic in a rotating mold.
Main Steps: Powder loading → Mold rotation → Cooling → Part removal
Advantages: Large parts, low stress
Disadvantages: Slow process
Applications: Water tanks, toys

2.6 Contact Moulding

What is it? Manual shaping of fiber-reinforced plastics.
Main Steps: Mold preparation → Resin application → Fiber placement → Curing → Part removal
Advantages: Large parts, low equipment cost
Disadvantages: Labor-intensive
Applications: Boat hulls, wind turbine blades

2.7 Continuous Extrusion (Plastics)

What is it? Continuous production of plastic profiles.
Main Steps: Granule feeding → Melting → Extrusion → Cooling → Cutting
Advantages: Continuous production, low cost
Disadvantages: Limited geometries
Applications: PVC pipes, plastic profiles

3. Metal Forming and Other Methods

3.1 Closed Die Forging

What is it? Forging of a metal part between dies.
Main Steps: Workpiece preparation → Preforming → Final forming → Flash trimming
Advantages: High strength, good metal flow
Disadvantages: High equipment cost
Applications: Crankshafts, gears

3.2 Cold Forming

What is it? Plastic deformation of metal at room temperature.
Main Steps: Material preparation → Forming → Finishing operations
Advantages: Work hardening, high tolerances
Disadvantages: High force requirement
Applications: Sheet metal parts, fasteners

3.3 Cold Heading

What is it? Cutting wire and forming its head.
Main Steps: Wire feeding → Cutting → Heading → Threading (if required)
Advantages: High production speed, minimal scrap
Disadvantages: Complex equipment
Applications: Bolts, screws, rivets

3.4 Sheet Metal Shearing

What is it? Cutting of sheet metals.
Main Steps: Sheet positioning → Cutting → Edge finishing
Advantages: Fast, low cost
Disadvantages: Limited cutting quality
Applications: Automotive parts, electronic enclosures

3.5 Sheet Metal Forming

What is it? Shaping sheet metals by bending, drawing, and similar processes.
Main Steps: Cutting → Bending → Deep drawing → Finishing operations
Advantages: Various geometries, fast production
Disadvantages: Mold cost
Applications: White goods parts, automotive panels

3.6 Spinning

What is it? Shaping a rotating metal sheet.
Main Steps: Sheet securing → Rotation → Forming → Finishing
Advantages: Low equipment cost, symmetrical parts
Disadvantages: Labor-intensive
Applications: Metal containers, lighting components

3.7 Powder Metallurgy

What is it? Compressing and sintering metal powders.
Main Steps: Powder preparation → Pressing → Sintering → Finishing operations
Advantages: Minimal scrap, complex parts
Disadvantages: High equipment cost
Applications: Gears, bearings

3.8 Continuous Extrusion (Metals)

What is it? Continuous production of metal rods or profiles.
Main Steps: Material feeding → Extrusion → Cooling → Cutting
Advantages: Continuous production, low cost
Disadvantages: Limited geometries
Applications: Aluminum profiles, wire conductors

4. Machining

4.A Automatic Machining

What is it? Computer-controlled machining using CNC machines.
Main Steps: CAD modeling → CAM programming → Machining → Inspection
Advantages: High precision, repeatability
Disadvantages: High investment cost
Applications: Tool making, aerospace components

4.M Manual Machining

What is it? Conventional machining controlled by an operator.
Main Steps: Part clamping → Machining → Measurement → Finishing
Advantages: Flexibility, low equipment cost
Disadvantages: Labor-intensive, high error margin
Applications: Small workshops, prototypes

5. Non-Traditional Machining

5.1 Electrical Discharge Machining (EDM)

What is it? Material removal using electrical discharges.
Main Steps: Electrode preparation → Dielectric fluid selection → Machining → Cleaning
Advantages: Hard materials, precise internal corners
Disadvantages: Slow, electrode wear
Applications: Tool making, precision cutters

5.2 Electrochemical Machining (ECM)

What is it? Material removal through electrochemical reaction.
Main Steps: Electrolyte selection → Current application → Machining → Cleaning
Advantages: No stress, hard materials
Disadvantages: Equipment cost, environmental impact
Applications: Turbine blades, precision components

5.3 Electron Beam Machining (EBM)

What is it? Micro-machining using high-energy electrons.
Main Steps: Vacuum creation → Electron beam focusing → Machining → Inspection
Advantages: Highly precise, small scale
Disadvantages: Requires vacuum, slow
Applications: Micro-holes, precision components

5.4 Laser Beam Machining (LBM)

What is it? Material processing using laser energy.
Main Steps: Laser focusing → Machining → Cooling → Cleaning
Advantages: Non-contact, precise cutting
Disadvantages: High energy consumption
Applications: Cutting, welding, marking

5.5 Chemical Machining

What is it? Shaping through chemical etching.
Main Steps: Masking → Etching → Cleaning → Inspection
Advantages: No stress, thin parts
Disadvantages: Environmental impact, slow
Applications: Precision metal parts, printed circuit boards

5.6 Ultrasonic Machining

What is it? Material removal using ultrasonic vibration.
Main Steps: Abrasive suspension preparation → Vibration application → Machining → Cleaning
Advantages: Brittle materials, precise machining
Disadvantages: Abrasive consumption, slow
Applications: Ceramics, glass processing

In conclusion, each manufacturing method has its unique advantages and limitations. For proper method selection, the following should be carefully evaluated:

Material properties
Part geometry and dimensions
Production volume
Cost factors
Quality and tolerance requirements

In modern manufacturing, combinations of these methods are often used, and new techniques are continuously being developed.

Manufacturing Process Selection

Manufacturing processes encompass fundamental shaping methods such as casting, molding, forming, and machining. The objective is to guide the selection of suitable manufacturing processes for a part. The manufacturing process selection strategy is outlined below; however, items 4, 5, and 6 apply to all selection strategies:

1. Estimate the annual production quantity.

2. Select a material type that meets the PDS.
3. Refer to the table to determine possibilities.
4. Evaluate each possibility in terms of engineering and economic requirements:

Understand the process and its variants.
Consider material compatibility.
Assess the conformity of the part concept with design rules.
Compare tolerance and surface quality requirements with process capability data.

5. Consider the economic positioning of the process and obtain part cost estimates for alternatives.
6. Review the selected manufacturing process in terms of operational requirements.

PDS: Product Design Specification
PRIMA: Process Information Map

Accordingly, the PRIMA manufacturing process selection matrix is based on two main variables:

Material type: Represents the compatibility of the primary material with the manufacturing process and is therefore a critical factor in technical selection. The majority of materials used in engineering production are included in this selection methodology.
Annual production quantity: The number of parts to be produced, used to determine the economic feasibility of the manufacturing process. The specified quantity ranges are as follows:
Very low volume = 1–100
Low volume = 100–1,000
Medium volume = 1,000–10,000
Medium-high volume = 10,000–100,000
High volume = 100,000+

Several cost factors, such as part size, geometry, tolerances, surface quality, capital equipment, and labor costs, influence manufacturing process selection. The rationale for basing the matrix on material and production quantity is to combine technological and economic considerations. By taking production quantity into account at early stages, it is possible to determine the most economical option during development. However, the economic production limits may be uncertain due to multiple influencing factors; therefore, the matrix primarily focuses on material usage. Because it is constrained in this manner, the matrix should not be viewed as comprehensive or interpreted as an absolute selection method. It reflects common industrial practices, but exceptions will exist at this level of detail. The matrix primarily serves as a first-level filtering tool, aiming to highlight the most suitable possibilities based on critical factors such as material and production quantity.

PRIMA Table