Different fabrication methods for custom part
Casting – is a custom fabrication process where solid metal is melted and heated to proper temperature then poured into a cavity or mold that has the exact shape required. After solidification, the end result has the exact configuration required for a metal part. Most custom metal fabricating shops prefer casting because they can produce cast parts that range in size from a fraction of an inch to over 30 feet in length while weighing several tons. Casting has the advantage of being able to produce complex shapes and parts with internal cavities and irregularly curved surfaces from metals that are difficult to machine. Casting allows custom metal fabricating that would otherwise be difficult or impossible through other fabrication techniques.
Extrusion – can produce custom metal parts economically because extrusion dies can be produced faster than forming dies and casting molds. Shorter lead times mean production that runs faster than most processes. Compared to other custom metal fabricating processes like casting, extruded parts usually have a finished structure with relatively close dimensional control. Casting molds are also more expensive than similar extrusion dies. While many different kinds of metals can be extruded, aluminum is considered as the best extrusion metal because of its unique combination of properties. Aluminum has high strength-to-weight ratio and highly resistant to corrosion. Using aluminum can make the custom part or component more cost effective without compromising quality and durability.
Forging – can either be cold or hot forging but they deliver similar results. In forging, metal is deformed into a predetermined shape using various tools and equipment. In hot forging, metal is heated to a temperature that reaches above its recrystallization point while in cold forging; metal is deformed below its recrystallization point. Cold forging is generally used for soft metals like aluminum or carbon alloy steels. Cold forging is less expensive than hot forging and the product requires very little finishing work. Cold forging is also less susceptible to contamination problems which make it a good choice for custom metal fabrication.
There are other common metal fabrication processes in the production of custom parts like turning, milling and drilling where cutting tools are used to remove material from a piece of metal. The fabrication method for a custom part usually depends on the part geometry, its intended purpose and the material used for the project. Some custom metal products may require secondary finishing to achieve their specific dimensions. Assembly may also be necessary to combine two or more parts together to become a single functional unit.