3.2 Engineering manufacturing processes

Students should have knowledge and understanding of the following manufacturing processes and techniques. They will be expected to demonstrate knowledge of:

  • which process is appropriate for specific materials
  • how these processes would be carried out.

Students will not be expected to have practical experience of using all of these processes but exam questions could refer to any of them.

Additive manufacturing

Subject content Additional information Mathematical understanding
  • Fused deposition.
  • Sintering (for metals).
  • Rapid prototyping (for polymers).
   

Material removal

Subject content Additional information Mathematical understanding
Cutting:
  • sawing
  • shearing
  • laser.
  Calculation of cutting speeds M1.1
Turning:
  • cylindrical
  • tapered
  • boring.
  Calculation of angles M1.6, M1.7
Milling:
  • face
  • slot.
   
Drilling:
  • using a pillar drill
  • centre drilling in the lathe.
  Calculation and selection of spindle speeds M2.3
Chemical etching:
  • PCB manufacture (alternative manufacturing methods will also be accepted).
   

Shaping

Subject content Additional information Mathematical understanding
Shaping by forming and manipulation:
  • bending
  • folding
  • press forming
  • composite lay up
  • punching
  • stamping.
  Calculation of:
  • angles
  • tolerances
  • pressure or force.
M1.1, M1.2, M1.5, M1.6, E10

Casting and moulding

Subject content Additional information Mathematical understanding
  • Pressure die casting.
  • Sand casting.
  • Injection moulding.
   

Joining and assembly

Subject content Additional information Mathematical understanding
Permanent and temporary methods:
  • rivets
  • threaded fastenings
  • soldering (soft and hard)
  • brazing
  • welding.
   

Heat and chemical treatment

Subject content Additional information Mathematical understanding
  • Normalising.
  • Annealing.
  • Hardening.
  • Quenching.
   

Surface finishing

Subject content Additional information Mathematical understanding
  • Painting.
  • Dip coating.
  • Electroplating.
  • Galvanising.
  • Polishing.