Course 13 | Core
Manufacturing Processes
Learn casting, forming, machining, joining, polymers, additive manufacturing, metrology, quality, and production tradeoffs.
Course snapshot
- Purpose
- Manufacturing Processes turns designs into real parts with process limits, tolerances, cost, inspection, and quality in view.
- Next in the guided sequence
- Used in Career Directions
How to study this course
- Define the part function
- Identify material and geometry constraints
- Choose a feasible process
- Estimate tolerances, cost, and quality risks
- Check manufacturability and inspection method
How this course is designed
Original course map
This course uses an original MechCompass module order using prerequisite logic, standard engineering practice, and evidence tasks. Suggested references are optional and listed separately.
Process families and selection
Every process is placed in one of a few families, shaping from liquid, from solid by deformation, by removal, by joining, or by addition, and each module names the parts and volumes it suits best.
Models before formulas
The habit is to picture the process, the metal flowing, the chip forming, the weld pool, then reach for the force, time, or cost equation. Numbers come after the mechanism is clear.
The 10 modules
01 | Module
Introduction to Manufacturing
The process families, design for manufacturing, and choosing a process by part and volume.
02 | Module
Metal Casting
Solidification, Chvorinov's rule, and sand, die, and investment casting.
03 | Module
Bulk Deformation: Rolling, Forging, Extrusion
Shaping metal by plastic flow, and the forces and work it demands.
04 | Module
Sheet-Metal Forming
Shearing, bending, deep drawing, and the springback that fights tolerances.
05 | Module
Theory of Metal Cutting
Chip formation, Merchant's circle, and cutting forces and power.
06 | Module
Machining Processes and Tool Life
Turning, milling, drilling, grinding, material removal rate, and Taylor tool life.
07 | Module
Joining and Welding
Fusion welding, heat input, the heat-affected zone, and weld quality.
08 | Module
Polymer Processing and Additive
Injection moulding and additive manufacturing, from prototype to production.
09 | Module
Metrology, Tolerances, and Quality
Fits and tolerances, GD&T, and statistical process control with Cp and Cpk.
10 | Module
Automation, CNC, and Economics
CNC and automation, manufacturing cost, and break-even process selection.