Topic 3 of 6 · Form 5
Manufacturing processes
One-off, batch, mass and continuous production; just-in-time; flexible manufacturing systems.
Notes for this topic 1 file, in order
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Shaping processes
- Casting: sand casting, die casting, investment casting.
- Moulding polymers: injection moulding (buckets, bottle caps), blow moulding (bottles), extrusion (pipes), vacuum forming (packaging), rotational moulding (water tanks).
- Forming metals: forging, rolling, pressing, deep drawing, bending.
- Machining: turning, milling, drilling, grinding; CNC machining.
- Fabrication: joining by welding, brazing, soldering, adhesives, mechanical fixings.
Production scales
One-off, batch, mass and continuous production; just-in-time; flexible manufacturing systems.
Quality
Quality control (inspection, tolerances, go/no-go gauges) and quality assurance (ISO 9001, total quality management).
CAD/CAM and automation
CNC, robotics, 3D printing (additive manufacturing) and laser cutting; benefits of precision and repeatability versus cost and job changes.
Health and safety
Risk assessments, COSHH-type controls for hazardous substances, guarding, PPE.
Exam tip: Choose a process that suits the material, product geometry and production volume – explain all three.
Check yourself
- Which process makes plastic water tanks?
- Give one advantage of injection moulding for mass production.
- What is additive manufacturing?
Show answers
- Rotational moulding.
- Any one: fast cycle times, high accuracy, complex shapes, low unit cost at volume.
- Building objects layer by layer from a digital model (e.g. 3D printing).
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