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Comparing Production Processes

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Mr S Hide

on 26 March 2015

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Transcript of Comparing Production Processes

How does it work?
What are the advantages/disadvantages?
What are the advantages and disadvantages?
Injection Moulding vs Vacuum Forming
3D printing
Pultrusion Processs
Vacuum Forming
Man recovers after 3D Printed Titanium Skull replacement
Advantages of 3D Printing

1. Ability to customize products

2. Rapid production of prototypes

3. Low cost of production

4. No storage cost

6. Quick availability of organs via bio printers.

Disadvantages of 3D Printing

1. Intellectual property issues

2. Unchecked production of dangerous items

3. Limitations of size

4. Limitations of raw material

5. Cost of printers

BTEC Engineering Level 2
Wednesday 25th March 2015
Period 1
How does it work?
Injection Moulding
Injection moulding is a very economical way of producing good-quality plastic components time after time.

1. An injection mould tool is produced and then placed into a press.

2. The required plastic material is heated and then forced into the mould where it is allowed to cool slightly to retain its shape.

3. The mould tool will then open and the component is ejected and falls to the bottom of the press.

4. The press then closes and the process starts over again.
Comparing Production Processes
Consider the environmental impact that your engineered product has throughout its lifetime.
Discuss as a group the advantages and disadvantages of Vacuum Forming.

Ability to create large parts
Relatively fast prototyping and production time frames
Lower start up costs
Patterns and molds can be made inexpensively from MDF, high density foams and epoxy
Ideal for repeat jobs aluminum castings can be made which have virtually unlimited lifetimes

Disadvantages of Vacuum Forming

Intricacy of parts is limited
Some clear parts will exhibit “mark-off” (i.e., defects or dirt from mold will transfer to parts)
Consistent wall thickness is not possible — very deep parts can be problematic
Only one material can be formed at a time
Finishing costs can be costly and labor intensive
What are the advantages/disadvantages?
Advantages of Injection Moulding

1. Allows for high production output rates
2. Can use inserts within the mold and fillers for added strength
3. Close tolerances on small intricate parts are possible
4. More than one material can be used at the same time when utilizing co-injection molding
5. Very little waste – all scrap can be reground to be reused
6. Full automation is possible
7. Lower cost-per-part compared to vacuum forming

Disadvantages of Injection Moulding

1. Extremely high start-up costs
2. Requires a great deal of engineering time
3. Long time frames necessary to fabricate tooling, making time-to-market a major drawback

Full transcript