After deciding on the precision manufacturing technique you want to use, you have to choose the right and most appropriate material. This is unarguably one of the most important steps in product development as it determines the functionality, aesthetics, and cost of the final part. Using the right material will ensure that the manufactured parts meet quality standards and industry specifications.

Are you new to manufacturing or looking to explore? You are in the right place. This article will be your guide on precision manufacturing materials. It will explain the different engineering materials available and the factors to consider before using any metal or plastic. 

Common Materials for Precision Manufacturing Projects

There are different materials you can use in product development. They have unique material properties and come with their advantages and disadvantages. Let’s look at some of the most common materials for precision manufacturing projects. 

1. Metals 

Metals are the most popular materials used in part manufacturing. They are durable, corrosion-resistant, and can withstand harsh conditions. Additionally, metals have a shiny appearance which can be further processed to improve aesthetics and performance. They are ductile and you can easily work on them. Some of the most popular metals for precision manufacturing include aluminum, titanium, steel, magnesium, and copper.

• Aluminum

Aluminum is a lightweight metal with a silvery and shiny appearance. It is strong and durable. It is straightforward to machine and cast aluminum alloys to create functional and high-quality parts. This metal is affordable and easily accessible. 

• Titanium

Another metal you can use is titanium. This metal is lightweight with high strength. The low melting point of titanium prevents overheating when cutting through. Additionally, titanium is biocompatible and is ideal when manufacturing medical devices.

• Steel

Steel is known for its corrosion and wear resistance. The different types of steel contain mainly iron which makes them good for applications that require a magnetic field. Steel contains varying quantities of other elements that enhance malleability and weldability. 

• Magnesium

Magnesium is a popular metal used across many manufacturing industries. It is lightweight and has a low melting point. You can use magnesium alone as an alloy with other elements such as manganese and silicon. Magnesium enhances the thermal and electrical conductivity properties of these materials. 

• Copper

Copper and its alloys are suitable candidates for manufacturing applications. They have an attractive appearance and resist degradation when exposed to corrosive substances. Copper has remarkable antibacterial properties. It is suitable for sterile uses as it kills microorganisms that come in contact with it. 

2. Plastics

Another category of material you can use for precision manufacturing is plastics. From rapid prototyping to mass production, plastics are compatible with different fabrication techniques including CNC machining, 3D printing, and casting. Common types of plastics used in product development include 

• Acrylic

Acrylic, also known as plexiglass, is a popular plastic suitable for both indoor and outdoor applications. It is optically clear and one can easily see through it. Acrylic is lightweight and durable. Furthermore, this plastic is scratch and impact-resistant. 

• Acrylonitrile Butadiene Styrene (ABS)

ABS is a thermoplastic polymer with excellent insulating properties. It has moderate hardness and the final parts have a glossy surface finish that may not need to be further processed. Additionally, ABS is thermally stable and won’t break down at extreme temperatures. 

• High-Density Polyethylene (HDPE)

Part manufacturers use HDPE extensively because of its many properties. HDPE is easily moldable which makes it a good candidate for injection molding operation. Furthermore, it is hard, strong, and highly recyclable. 

• Acetal

Acetal or polyoxymethylene is a general-purpose plastic with good dimensional stability. It has a high strength and low friction. Acetal is wear and chemical resistant. You can use it for industrial components such as bearings and bushings. 

3. Composites

Composites are the product of mixing reinforcements such as carbon fibers and glass fibers with matrices. The result is a material with an excellent strength-to-weight ratio. Composites are known for their stability in high-temperature environments and low thermal expansion. This engineering material has applications in manufacturing aerospace wing spars and electronic circuit boards. 

4. Woods

The use of wood in precision manufacturing is nothing new. They are indispensable in many applications because of their machinability when cutting them with advanced technology. Woods can either be hard or soft. Examples of hardwood include oak, walnut, and maple. They are durable and workable. Softwoods such as cedar and pine are more affordable and readily accessible. 

Key Considerations for Choosing the Right Materials for Your Precision Manufacturing Projects

With the many types of materials available, choosing the right one for your project can be a daunting task. There is no straightforward approach to go about this as you need to carefully examine certain factors. The following are key considerations you should keep in mind when selecting the right material during part fabrication.

1. Workability

You have to consider how easy it would be to manipulate the material and create the final part. Based on the specific technology you want to use, you should check for machinability, castability, and moldability. 

You define this property based on strength, thermal sensitivity, and tendency to cause tool wear. You should go for materials with moderate hardness and those easy to cut through. It should not be too tough that it causes significant damage to the cutting tool. This will help reduce production time, maximize cost, and improve overall productivity. 

2. Part Weight

Another important factor to consider is the desired strength-to-weight ratio of the part. Different materials have unique weight and strength properties. Generally, metals are stronger than most plastics and polymers. Conversely, plastics are lighter in weight. 

However, there are some metals and plastics that have a balance. If weight is a determining factor, you should go for materials such as titanium, magnesium, nylon, and ABS. Using lightweight materials makes the manufacturing process easier and reduces labor costs. 

3. Part Aesthetics

You should also factor in the visual aspect of the manufactured component. This is important as it will influence purchasing decisions and may influence how well your product sells in the market. When aesthetics is important, the material should have a top-notch and glossy look. This will ensure the final parts are appealing to the customers. 

Furthermore, the material must be able to be compatible with the particular surface finishing technique you want to use. Be sure it can be painted, plated, anodized, or coated as needed. 

4. Part Accuracy and Tolerance 

The level of accuracy and tolerance you want to achieve will determine the material you will use. Though used interchangeably, these two terms are different. Accuracy describes how well the final part closely resembles the initial design. On the other hand, tolerance tells the permissible deviation of the part from specified dimensions. 

Certain materials come with innate dimensional stability. They are stiff and easier to machine. This makes them suitable for applications where parts must be accurate for them to function properly. 

5. Cost and Availability

The material cost is a significant aspect of the total cost and it will affect the price of the final part. The cost of the material varies which depends on availability and how easy it is to manufacture them. Generally, carbon fiber composites are more expensive when compared to most metals and plastics. Between plastics and metals, there are also significant price differences. 

In addition to the material cost, you should also keep in mind processing expenses and ease of recyclability. Those that are difficult to machine will come with higher processing costs. Furthermore, metals such as aluminum and steel are easy to recycle. Hence, they are more cost-effective in the long run. 

6. Part Applications

The particular applications and places you want to use the part also play a huge role. You have to determine the structural strength, thermal resistance, and chemical resistance of the material before using it. You should also consider environmental factors and conditions the components will be exposed to. 

Furthermore, some industries have specific requirements. For instance, auto parts ought to be lightweight and strong to enhance fuel efficiency. Additionally, the materials you use for medical and surgical instruments must be compatible with bodily fluids and tissue. 

Conclusion

Using the wrong material when manufacturing can lead to performance failures and poor aesthetic quality. When selecting a material for your precision manufacturing project, you have to first define your aims and what you want to achieve. You then assess material options and determine critical properties. Thereafter, test the material and make your final decision. Still confused? Reach out to experts and engineers from Zintilon to avoid mistakes.