5 - Major developments in technology - New methods of manufacture

Question 1

Name 5 new methods of manufacture

Answer 1

• Electrohydraulic forming
• Direct metal laser sintering (DMLS)
• Fibre injection moulding
• Laser beam welding
• Physical vapour deposition (finishing process)

Question 2

Electrohydraulic forming

Answer 2

Sheet metal forced against a former by a shockwave from an electrical spark in a water tank.

• Uses one-sided former
• Fast
• Great detail is possible
• Material is evenly distributed

Electrical appliance cases, Car parts

Question 3

Direct Metal Laser Sintering (DMLS)

Answer 3

Advanced 3D printing of metals. Metal particles are fused layer by layer with a laser.

• Complex, strong and lightweight parts can be made
• Undercuts and internal voids are possible

One-off prototypes and test parts

Question 4

Fibre injection moulding

Answer 4

Injection moulding using pellets of glass or carbon-fibre filled polymer, such as nylon.

• Parts produced are strong, stiff, lightweight and cheap to mould
• Sustainable as carbon-fibre waste is reused

Lightweight parts for cars, aerospace equipment, sports equipment

Question 5

Laser beam welding

Answer 5

Intense heat of a laser beam is used to join multiple pieces of metal

• Faster than MIG and TIG welding
• Makes narrower, deeper welds possible
• Dissimilar metals can be welded
• Reduces distortion
• No finish is needed
• Welds thin sheets

Shipbuilding, construction, cars and railway equipment

Question 6

Physical vapour deposition (finishing process)

Answer 6

Base material is vapourised, thin layer is deposited

• Abrasion resistance
• Durability
• Large range of materials
• Uniform, even deposition

Semi-conductor (computer) components, food packaging, machine tool tips, decorative products