Processing Materials
- Apr 17, 2016
- 2 min read
Recently I defined my materials as follows
Retrofitting Brace Body: Processed Aluminium
Locking Mechanism Plates: Stainless Steel
Main Light Housing Body: ASA (Acrylonitrile Styrene Acrylate)
Main Body "Wings": Processed Aluminium, Underside White Reflective Coating
Throwaway Components: POM (Polyoxymethylene) housing, Aluminium Plating
I used the book "Making It" by Chris Lefteri to define the production processes for each material and show I have considered the manufacturing aspects of the proposal. Processes for each material are as follows:
The Aluminium Components will be formed via High Pressure Die Casting. This process is fast and specific for high volume production, and is ideal for producing complex shapes and thin walled metal components. It leaves an excellent surface finish and has dimensional accuracy.
The Locking Mechanism Stainless Steel Plates will be produced via the Metal Injection Molding process. This is a new process that allows metals like stainless steel to be formed in complex shapes as plastics can in the standard injection molding process. High volume production is needed to justify the cost of tooling, but thee is a very low price per unit cost. Speed fast like standard injection molding, and complex shapes can be formed with a quality finish. The accuracy of the process (0.10 of a millimeter) is suitable given the need for a tight fitting lock.
I would use the Insert Molding Injection molding variant process to create the two plastic components in POM and ASA. This allows the meal conductivity components to be inserted into the form while the plastic is molded which will save on further production costs. It is ideal for high volume production, and can form complex shapes as like injection molding. Importantly it has a fine dimensional accuracy of 0.1 of a millimeter.
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