February 20, 2023
By:EmpoweringCPO Insights Team

Innovative Production Methods (Metal Machining, Casting, Stamping & Bending)

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This report gives insights into Innovative Production methods like metal machining, casting, stamping & Bending, processes and advantages of each method, contributing factors for potential savings, leading suppliers, and many other details on this category. This research report by our team of experienced professionals can help the procurement team to benchmark the current contract with the market. EmpoweringCPO can help your organization with Procurement Reports of various categories to predict and achieve savings.

Abstract

  • Electro-Chemical Machining or ECM as is popularly known is a process capable to produce parts of complex geometry, intricate shapes, and deburr parts with defined edge formation.
  • Electro Chemical Machining (ECM) could be used for machining all electroconductive metals and alloys. The applications of ECM are the Machining of hard materials, heat-resistant materials, and Die sinking.
  • 3D Printing is a process for making a physical object from a three-dimensional digital model, typically by laying down many successive thin layers of material.
  • Powder bed fusion (PBF) is a subset of additive manufacturing (AM) whereby a heat source (laser, thermal print head) is used to consolidate material in powder form to form three-dimensional (3D) objects.
  • PBF processes have an advantage over many other AM processes in that they do not require a support structure, as overhangs and unconnected islands are supported by the surrounding unfused powder bed.
  • The powder bed fusion process can use any powder-based material, but the following materials are the most common: Nylon, Stainless Steel, Titanium, Aluminium, and Cobalt Chrome.
  • Hybrid Manufacturing Techniques offer clear advantages, combining a high deposition rate together with the accuracy and surface finish associated with machining.
  • Support-free geometries, Uniform powder bed, and Production grade quality are the main features of Sapphire that differentiate it from Hybrid technologies.
  • 3D Printed Sand Casting is the alternative to Conventional Casting, in which producing sand molds and cores without tools makes economical production possible, from individual parts to small batches.
  • 3D sand casting combines the advantages of traditional cast methods and 3D printing technology to form a more productive casting process.
  • The AFM process provides high-quality results for machined components that require the removal of imperfections created by mechanical processes.
  • The absence of Strain, high precision and repeatability, Economical tools, and low production costs are some of the advantages of using the Elastoforming process.
  • Hydroforming is an ideal process for prototyping and part development, with just small adjustments to the tooling and material thickness, new and improved parts in small runs can be produced.
  • Progressive die stamping consists of several individual workstations, each of which performs one or more different operations on the part which is carried from station to station by a stock strip.
  • Transfer die stamping tends to be more economical If a part has features like cut-outs, pierced holes, ribs, knurls, or threading.
  • High speed, low labor cost, and low scrap material are advantages of progressive die stamping while Transfer dies stamping requires one press to operate multiple tools.
  • Electrochemical and 3D Printing / Additive Manufacturing Machining do not require tools, thus saving the tool cost used in conventional processes.
  • With 3D Printed Sand Casting, parts can be made in short delivery times with a very high degree of flexibility.
  • High speed of product processing and large production runs with minimum die degradation are some of the advantages of Progressive stamping.
  • Europe and USA are the market leaders in advanced machining processes like 3D printing / Additive manufacturing, Electrochemical machining, Hydroforming, and Elastoforming.

Table of Content

ContentSlide No.
Executive Summary3
Electro-Chemical Machining – Introduction4
Electro-Chemical Machining – Advantages5
Electro-Chemical Machining – Applications6
3D Printing & Additive Manufacturing – Introduction7
Powder Bed Fusion Techniques8
Comparison of Powder bed fusion processes9
Powder Bed Fusion – Process10
Powder Bed Fusion – Advantages and Disadvantages11
Hybrid Manufacturing Techniques12
Machine Description – INTEGREX i-40013
Machine Characteristics – INTEGREX i-40014
VELO3D’s Sapphire – Introduction15
VELO3D’s Sapphire – Advantages16
3D Printed Sand Casting17
3D Printed Sand Casting – Advantages18
Abrasive Flow Machining (AFM)19
Abrasive Flow Machining (AFM) – Applications20
Abrasive Flow Machining (AFM) – Advantages21
Elastoforming – Introduction22
Elastoforming – Advantage23
Hydroforming – Introduction24
Hydroforming – working25
Hydroforming – Advantage26
Progressive die stamping – Introduction27
Progressive die stamping – Working28
Transfer Die – Introduction29
Comparison of Advantages30
Advanced Roll Forming31
Roll Forming Advantages32
Potential Savings – Contributing Factors33-36
Supplier List37

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Compliance management is very critical as otherwise the procurement organization may run into a scenario where there is a huge gap between realized savings and reported savings. Many procurement functions estimate large savings numbers when contracts are signed. They also invest significant time and effort in negotiating contracts for necessary goods and services, only to have a third or more of their purchasing dollars flow outside those deals. Some of the obvious fall-outs of non-compliance and maverick purchases are:

  • Very high prices
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  • Vendor Compliance
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