Joining Methods

Question 1

3 types of manufacture methods

Answer 1

Redistribution
Wasting
Fabrication

Question 2

What is Redistribution (1)

Answer 2

Making products/components by moulding, casting or pressing

Question 3

Example of a product made with Redistribution

Answer 3

Bosch hammer drill casing (injection moulded ABS)

Question 4

Benefits of Redistribution (6)

Answer 4

• Speed of production (much faster than fabrication in high volume production)
• Complexity (ergonomic grips can be created)
• Integrated fastening methods (holes for self-tapping screws and “click” fastenings can be moulded)
• Standardised products
• Impossible to achieve same design with fabrication
• Tough construction with few joints

Question 5

Disadvantages of Redistribution (2)

Answer 5

• High set up cost for injection-moulding dies

- Dedicated equipment - Dies can only make one kind of case, vulnerable to change in market demand

Question 6

What is wasting (2)

Answer 6

• Making products by removing material

- e.g. Turning, milling, grinding and spark erosion

Question 7

Example of product made by wasting

Answer 7

Parker stainless steel biro (CNC turning)

Question 8

Advantages of wasting (4)

Answer 8

High quality surface finish
Precision - engineered product requiring manufacture to fine tolerances
Interchangeable parts for pen require machining of screw threads
High speed, high volume when linked with CNC

Question 9

Disadvantages of Wasting (2)

Answer 9

Waste produced such as swarf, which is recovered and recycled adding cost
Materials such as stainless steel are very hard so require expensive cutting tools

Question 10

What is fabrication (2)

Answer 10

Manufacture of products with permanent joints joining components
E.g. Welding, gluing, riveting or temporary lol screws nuts and bolts

Question 11

Example of product made from fabrication

Answer 11

Aluminium bike frame by welding

Question 12

Benefits of fabrication (4)

Answer 12

Products can be made to individual customer specification like bike size with body type
Relatively simple equipment required with less investment
Flexible manufacture - same equipment can be used to fabricate many types of products
Job satisfaction from “building” products from raw materials

Question 13

Disadvantages of fabrication (4)

Answer 13

Highly skilled job demands high salary
Can be unpleasant to work in areas such as welding, with fumes, heat and flash etc
Requires good management of health and safety
Relatively slow production compared to other methods