Name:
Period:
Date:
Background
Manufacturers select processes by considering material, geometry, production quantity, accuracy, surface finish, cost, and lead time.
| Process | Best suited for | Main limitation |
|---|---|---|
| 3D printing | Complex prototypes and low quantities | Slow per part; layered finish |
| CNC machining | Accurate metal or plastic parts | Material waste; machine time |
| Injection molding | Large quantities of plastic parts | High mold cost |
| Casting | Complex metal shapes | Tooling and finishing may be needed |
| Sheet-metal forming | Brackets, covers, and enclosures | Limited by bends and tooling |
| Laser cutting | Flat sheet profiles | Primarily two-dimensional cuts |
1. Select a Primary Process
| Product | Requirements | Selected process | Reason |
|---|---|---|---|
| 10 custom robot sensor brackets | Aluminum; ±0.25 mm; needed next week | ||
| 100,000 plastic bottle caps | Low cost; identical; threaded | ||
| One prototype drone housing | Complex internal features; lightweight plastic | ||
| 2,000 steel electrical enclosures | Flat panels with bends and holes | ||
| 50 decorative aluminum signs | Flat profiles and engraved text |
2. Production Planning
Choose one product above and create a process sequence from raw material to finished inspection.
3. Quantity Change
The robot bracket order increases from 10 parts to 20,000 parts per year.
- Would you keep the same process? Explain.
- What tooling or process might become economical?
- What quality checks would still be required?
4. Recommendation
Explain why “the fastest machine” is not always the best manufacturing choice. Use two examples from the activity.
Submission Checklist
- All analysis questions are answered.
- Required calculations, tables, sketches, or diagrams are complete.
- The final recommendation uses evidence from the lesson.
- Your name, class period, and date are included.
Closing Reflection
What was the most important engineering or manufacturing decision you made in this lesson? Explain why it mattered.