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Design Guide

Find and compare the right manufacturing process for your part. Browse our 13 metal manufacturing processes by family and material, review full specifications and design notes, and compare up to three side by side.

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Showing all 13 processes. Select up to three to compare.

01Casting

Sand Castings

Best for large or hollow parts, from a few pieces to large quantities.

  • Aluminum
  • Iron
  • Steel
Tolerance
1/16" - 1/8" per foot
Surface Finish
250-300 rms
Tooling Cost
Low
Best Production Volume
Few pieces to large quantities
Direct Labor Cost
High
Full specifications
Materials
Aluminum, Iron, Steel
Process
Fluid metal poured into a cavity or form of sand without external pressure
Complexity
Considerable - many shapes and ribs possible
Size Range
1" to huge
Wall Thickness
0.250" min. preferred (0.090" possible)
Tolerance
1/16" - 1/8" per foot, greater for larger sizes
Draft Angle
3° minimum
Corner Radii
Generous; at least 1 rib thickness, constant wall section preferred
Surface Finish
250-300 rms
Tooling Cost
Low (0.25; plastic injection molding = 1.00)
Best Production Volume
Few pieces to large quantities
Direct Labor Cost
High (labor intensive)
Finishing Cost
High (much finishing required)
Scrap Cost
Moderate (recyclable)

Design Features

  • Basic casting method of the industry
  • Good for low volume parts
  • Large, moderate to high strength parts possible
  • Hollow shapes possible with cores
  • Section transitions must be gentle
  • Parts must generally be machined if mating with other parts; machining material allowances required
  • Closer tolerances (1/32" - 3/32" per ft.) with better surface finish (150-250 rms) possible via Shell Molding, offset by higher tool cost at larger quantities
Discuss Your Part

02Casting

Permanent Mold Castings

Best for moderate-size parts in substantial quantities with good surface finish.

  • Aluminum
  • Brass
  • Magnesium (some Iron)
Tolerance
0.032" - 0.100" per foot
Surface Finish
90-125 rms
Tooling Cost
Medium
Best Production Volume
1,000/run & up
Direct Labor Cost
Moderate
Full specifications
Materials
Aluminum, Brass, Magnesium (some Iron)
Process
Fluid metal poured into metal molds and around metal cores without external pressure
Complexity
Moderate - metal molds somewhat limit shapes
Size Range
Moderate
Wall Thickness
0.100" minimum
Tolerance
0.032" - 0.100" per foot
Draft Angle
3°
Corner Radii
0.060" minimum
Surface Finish
90-125 rms
Tooling Cost
Medium (0.50-0.75; plastic injection molding = 1.00)
Best Production Volume
1,000/run & up
Direct Labor Cost
Moderate
Finishing Cost
Low to moderate - less labor than sand casting
Scrap Cost
Low (recyclable)

Design Features

  • Economic with substantial quantities
  • Stronger than die castings
  • Relatively close tolerances achievable
  • Good surface finish
  • Machining may be required
  • Smaller radii and thinner sections than sand casting - smaller parts possible
Discuss Your Part

03Casting

Lost Foam Castings

Best for closer tolerances and thinner walls than sand casting allows.

  • Aluminum
  • Iron (Steel possible with special handling)
Tolerance
0.030"/in.
Surface Finish
200-250 rms
Tooling Cost
High
Best Production Volume
Moderate
Direct Labor Cost
High
Full specifications
Materials
Aluminum, Iron (Steel possible with special handling)
Process
Fluid metal poured into a permeable shell formed around an expanded styrofoam bead form; the metal vaporizes the foam and takes its shape
Complexity
Considerable - more shapes and thinner walls than sand castings
Size Range
Moderate - determined by manufacturer’s flask size
Wall Thickness
0.060" minimum
Tolerance
0.030"/in. (small holes to ±0.005")
Draft Angle
2° minimum (less possible)
Corner Radii
0.060" minimum
Surface Finish
200-250 rms (depends on foam bead size)
Tooling Cost
High (1.25; plastic injection molding = 1.00)
Best Production Volume
Moderate (small quantities expensive)
Direct Labor Cost
High (much hand work)
Finishing Cost
Low to moderate
Scrap Cost
Low (recyclable)

Design Features

  • Often used to replace steel parts with iron
  • Used to reduce cost of aluminum parts
  • Hollow shapes possible
  • Closer tolerance and thinner parts than sand casting
Discuss Your Part

04Casting

Die Castings

Best for high-volume, thin-walled non-ferrous parts needing little finishing.

  • Aluminum
  • Zinc
  • ZA alloys
  • Lead
  • Magnesium
Tolerance
±0.003"/in.
Surface Finish
60-125 rms
Tooling Cost
High
Best Production Volume
Substantial quantities required
Direct Labor Cost
Low-Medium
Full specifications
Materials
Aluminum, Zinc, ZA alloys, Lead, Magnesium
Process
Fluid metal injected under pressure into precision molds mounted in special machines
Complexity
Considerable - intricate shapes, thin walls possible
Size Range
Moderate - determined by mold and machine size
Wall Thickness
0.025" minimum (thinner possible)
Tolerance
±0.003"/in. (0.001" possible with special handling)
Draft Angle
1° minimum (no draft possible)
Corner Radii
1 wall thickness (near 0 possible)
Surface Finish
60-125 rms
Tooling Cost
High (1.25; plastic injection molding = 1.00)
Best Production Volume
Substantial quantities required
Direct Labor Cost
Low-Medium
Finishing Cost
Low (little finishing required)
Scrap Cost
Low (recyclable)

Design Features

  • High volume parts most economical; molds capable of 100,000-300,000 parts
  • Hollow shapes possible; net shapes and sizes from mold
  • Materials have bearing properties; moderate to high strength parts
  • EMI shielding obtained with part; usable in pressure-tight assemblies
  • Parts may be inserted for threads, hubs, etc.
  • May be painted, anodized, polished, plated - good decorative applications
  • Trim dies may be required; limited to low melting temperature (non-ferrous) metals
  • Materials must be selected to eliminate galvanic corrosion
  • Prototyping via Plaster Mold Process - low tool cost, good quality, higher piece cost
Discuss Your Part

05Casting

Investment (Lost Wax) Castings

Best for steels in complex shapes and for accurate small parts.

  • All Steels (incl. Stainless)
  • Aluminum
  • Copper
  • Brass
  • Bronze (some Iron)
Tolerance
0.003"/in. possible
Surface Finish
90-125 rms
Tooling Cost
Low-Moderate
Best Production Volume
Wide range
Direct Labor Cost
High
Full specifications
Materials
All Steels (incl. Stainless), Aluminum, Copper, Brass, Bronze (some Iron)
Process
Fluid metal poured without external pressure into hollow shell molds formed around wax forms, with the wax melted out; aluminum tools required for wax forms
Complexity
Greatest of any casting method
Size Range
Moderate - determined by manufacturer’s flask size
Wall Thickness
0.010" minimum
Tolerance
0.003"/in. possible
Draft Angle
1°-3° (0° possible with special handling)
Corner Radii
0.02"-0.03" (0 radius possible)
Surface Finish
90-125 rms
Tooling Cost
Low-Moderate (0.25-0.75)
Best Production Volume
Wide range (depends on part size)
Direct Labor Cost
High (hand pouring, much hand work with wax forms)
Finishing Cost
Low (net parts possible; some secondary operations)
Scrap Cost
Low (recyclable)

Design Features

  • Best for steels needed in complex shapes
  • Good for accurate small parts; hollow parts with cores
  • High strength, net shape parts
  • Excellent tolerances and surface finish
  • Very economical for small parts; large parts limited by flask size
Discuss Your Part

06Machining

General Machining

Best for intricate shapes, excellent tolerances and almost any material.

  • Steel
  • Iron
  • Aluminum
  • Brass
  • Magnesium
Tolerance
±0.001" and less
Surface Finish
16 rms
Tooling Cost
Low to medium
Best Production Volume
Any size
Direct Labor Cost
Medium
Full specifications
Materials
Steel, Iron, Aluminum, Brass, Magnesium
Process
Broaching, milling, planing, shaping, grinding, polishing, machining centers, drilling, reaming, threading and gear cutting
Complexity
Great - tools or machines exist for most any intricate shape
Size Range
Great - limited only by machine capability
Tolerance
±0.001" and less
Corner Radii
Square corners possible; good design prefers radii
Surface Finish
16 rms (better with grinding, reaming, burnishing)
Tooling Cost
Low to medium (complex parts may need expensive fixturing; broaches can be expensive)
Best Production Volume
Any size; larger lots more economical
Direct Labor Cost
Medium (complicated parts can be high)
Finishing Cost
Low (depends on material and use)
Scrap Cost
Low (recyclable)

Design Features

  • Greatest variety of machinery of all metal working processes
  • Nearly any shape can be made, though possibly labor intensive
  • Excellent tolerances and surface finishes
  • Required secondary process for most other processes
  • Machinery exists to work almost any engineering material
Discuss Your Part

07Machining

Turning / Bar Stock Machining

Best for round profiles at the lowest tooling cost of any method.

  • Steel
  • Aluminum
  • Brass
Tolerance
±0.001" or less
Surface Finish
16 rms
Tooling Cost
Lowest of all metal working methods
Best Production Volume
Any size
Direct Labor Cost
Medium
Full specifications
Materials
Steel, Aluminum, Brass
Process
Lathe turning
Complexity
Limited to circular profiles
Size Range
Round stock; limited only by machine capability
Tolerance
±0.001" or less
Corner Radii
Square corners possible; part strength prefers some radius
Surface Finish
16 rms (better with secondary grinding)
Tooling Cost
Lowest of all metal working methods
Best Production Volume
Any size; larger lots more economical with CNC turning
Direct Labor Cost
Medium (low with automatic equipment)
Finishing Cost
Low
Scrap Cost
Low (recyclable)

Design Features

  • Lowest cost tooling of any production method
  • Sometimes poor material utilization
  • Excellent tolerances and surface finishes
  • Complex round shapes can be made
Discuss Your Part

08Forming & Fabrication

Stamping

Best economy for sheet-material parts, from one piece to millions.

  • Steel
  • Aluminum
  • Copper
  • Alloys
Tolerance
±0.003" holes/edges
Surface Finish
63-125 rms
Tooling Cost
Low to high
Best Production Volume
1 to millions
Direct Labor Cost
Medium
Full specifications
Materials
Steel, Aluminum, Copper, Alloys
Process
Blanking, forming, drawing sheet-thickness parts; formed shapes with progressive dies
Complexity
Very good - blank, form angles, punch holes, draw shapes, coin
Size Range
Great, but limited to sheet material
Sheet Thickness
Up to average 0.250"
Tolerance
±0.003" holes/edges; ±1° formed angles
Corner Radii
Minimum 1× thickness, near 0° with correct material
Surface Finish
63-125 rms (mill finish; smooth paintable or plating surface)
Tooling Cost
Low (simple) to high (drawn parts)
Best Production Volume
1 to millions
Direct Labor Cost
Medium
Finishing Cost
Low-Medium
Scrap Cost
Low (recyclable)

Design Features

  • Best economy for simple stampings
  • Material utilization needs attention
  • Progressive dies raise tooling costs; drawn parts require higher tooling costs
  • Edges can be smoothed by secondary operations if required
  • Tooling cost relative to number of dies and pieces needed
Discuss Your Part

09Forming & Fabrication

Fine Blanking

Best for precision blanks with clean, burr-free edges in one operation.

  • Steel
  • Aluminum
  • Copper
Tolerance
±0.003" holes/edges
Surface Finish
63-125 rms
Tooling Cost
Medium
Best Production Volume
1 to thousands
Direct Labor Cost
Low
Full specifications
Materials
Steel, Aluminum, Copper
Process
Precision stamped blanks in one operation without fractured edges, using a triple-action hydraulic press; eliminates shaving, reaming, grinding
Complexity
Limited to blanking, punching, some forming - without burrs and sharp edges
Size Range
Good, but limited to sheet material
Sheet Thickness
Up to 0.500"
Tolerance
±0.003" holes/edges; ±0.001" formed angles
Corner Radii
Minimum 1× thickness, near 0° with correct material
Surface Finish
63-125 rms (mill finish)
Tooling Cost
Medium (dies more complicated than regular stamping)
Best Production Volume
1 to thousands
Direct Labor Cost
Low
Finishing Cost
Low (less than stamping)
Scrap Cost
Low (recyclable)

Design Features

  • Best economy if all blanking done in one operation
  • No fractured edges as in stamping
  • Progressive dies allow some forming
  • Material utilization requires attention
Discuss Your Part

10Forming & Fabrication

Powdered Metal

Best for net-shape small parts in moderate to high volumes.

  • Iron
  • Steel
  • Copper
  • Bronze
  • Aluminum
  • Molybdenum
  • Tungsten
  • Tungsten Carbide
Tolerance
±0.001" to ±0.003" depending on material
Surface Finish
Porous parts
Tooling Cost
Relatively high
Best Production Volume
Moderate to high volume
Direct Labor Cost
Medium
Full specifications
Materials
Iron, Steel, Copper, Bronze, Aluminum, Molybdenum, Tungsten, Tungsten Carbide
Process
A measured amount of metal powder pressed into a die using large-tonnage presses; powder amount and press force control density and cohesion
Complexity
Considerable - uniform thickness and symmetry desirable, but many unique shapes possible
Size Range
Most parts under 5 lbs
Wall Thickness
0.040" minimum (less with special handling)
Tolerance
±0.001" to ±0.003" depending on material
Draft Angle
Normally not required
Corner Radii
Generous radii and fillets preferred; sharp edges possible
Surface Finish
Porous parts; 63 rms equaled easily
Tooling Cost
Relatively high - tooling subjected to high stresses
Best Production Volume
Moderate to high volume; some parts economical at 1,000 pieces
Direct Labor Cost
Medium
Finishing Cost
Low (all common finishing methods usable)
Scrap Cost
Low (recyclable)

Design Features

  • Alternate for some castings and machined parts
  • Net shape parts with holes, bosses, chamfers, keys, keyways, tapers, undercuts, flanges and irregular shapes
  • Two parts can be joined; porous filters and magnetic parts can be formed
  • Bearing materials can be oil impregnated for lubricity
  • Minimizes machining and scrap losses; close tolerances and good finish
  • Controlled porosity and density; large numbers of small parts cheaply
  • High strength parts may be a challenge
  • Dissimilar materials may be combined; refractory or reactive metals can be fabricated
Discuss Your Part

11Forming & Fabrication

Tube Fabrication

Best for frames and functional shapes bent from standard tubing.

  • Steel
  • Aluminum
Surface Finish
Mill finish of tubing
Tooling Cost
Low
Best Production Volume
Any size
Direct Labor Cost
High unless automated
Full specifications
Materials
Steel, Aluminum
Process
Bending of round, square, rectangular tubing into functional shapes; hole punching and coping possible
Complexity
Limited
Size Range
Limited only by bending equipment
Wall Thickness
All standard tubing walls
Tolerance
Depends on tubing diameter, wall thickness, length and complexity
Corner Radii
Limited by tubing material, diameter and wall thickness
Surface Finish
Mill finish of tubing
Tooling Cost
Low (most fixturing simple, fits existing bending tools)
Best Production Volume
Any size
Direct Labor Cost
High unless automated
Finishing Cost
Low (smooth finished part for painting or plating)
Scrap Cost
Low (recyclable)

Design Features

  • Many furniture applications
  • Excellent for frames of parts made of other material
  • Special attention to radii
  • Out-of-the-ordinary bends possible with special techniques
Discuss Your Part

12Forming & Fabrication

Wire Forms

Best for special shapes formed from wire, in any lot size.

  • Steel
  • Aluminum
  • Copper
Surface Finish
Mill finish of wire
Tooling Cost
Low
Best Production Volume
Any size
Direct Labor Cost
High unless automated
Full specifications
Materials
Steel, Aluminum, Copper
Process
Forming functional shapes from varying wire sizes and materials
Complexity
Very
Size Range
Limited by wire size, strength and rigidity
Tolerance
Depends on length, wire dimension and compatibility
Corner Radii
Limited by material and design
Surface Finish
Mill finish of wire
Tooling Cost
Low (most fixturing simple, fits existing tools)
Best Production Volume
Any size; larger lots more economical
Direct Labor Cost
High unless automated
Finishing Cost
Low (smooth finished part for painting or plating)
Scrap Cost
Low (recyclable)

Design Features

  • Pre-plated wire may be used to reduce finishing costs
  • Excellent for special shapes or uses
  • Can be made to conform to many odd shapes
Discuss Your Part

13Forming & Fabrication

Strainers

Best for screening and filtering assemblies, down to micron level.

  • Carbon Steel
  • Stainless Steel
  • Copper
  • Brass
  • Phosphor Bronze
  • Monel
  • Aluminum
  • Plastic
  • Galvanized Steel
Surface Finish
Determined by materials used
Tooling Cost
Low
Best Production Volume
Any size
Direct Labor Cost
Medium-High unless automated
Full specifications
Materials
Carbon Steel, Stainless Steel, Copper, Brass, Phosphor Bronze, Monel, Aluminum, Plastic, Galvanized Steel
Process
Fabrication of woven, molded, perforated, stamped or etched wire cloth/mesh into shapes for specialized screening and filtering applications
Complexity
Considerable - mainly by joining parts into an assembly; applications across aerospace, automotive, agricultural, chemical, medical, mining, energy and more
Size Range
Limited only by the designer’s imagination and the machinery
Sheet Thickness
0.002"-0.003" stainless steel available
Tolerance
Finished parts generally ±0.030" to ±0.060"
Corner Radii
As desired
Surface Finish
Determined by materials used (generally 63 rms or better)
Tooling Cost
Low (mostly custom work with forming or machining tools)
Best Production Volume
Any size (cost depends on part complexity)
Direct Labor Cost
Medium-High unless automated
Finishing Cost
Low (minimal finishing required)
Scrap Cost
Medium (multi-material parts may be difficult to dispose)

Design Features

  • Filters from large to micron filtering ability
  • Used for straining, filtering, screening, flame arresting, electrical and magnetic shielding, parts protection and more
  • Can combine or bond dissimilar materials in one assembly
Discuss Your Part

RMS = root-mean-square surface roughness in microinches; lower numbers are smoother.

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