1) Does anyone know of a manufacturing process instructor? Or a University that has a strong program in this field, preferably in Oregon.
2) Is it standard practice when getting manufacturing quotes to specify in detail the process/techniques to be used? Or do the manufacturers normally figure this out?
This is one of the most important things to know when you are designing a product.
There are some very good books that cover many of the processes available today, such as Handbook of Manufacturing Processes and Manufacturing Processes for Design Professionals. Both of these are available at Amazon and other book stores.
There is also a great list of manufacturing processes that is shown on mfgquote.com.
Lost wax is very expensive, if this is about the tool shown tonight, a simple grinding process would work. I worked at the lost wax factory in Redmond quite a few years ago. I didn't get a chance to corner you tonight. However, it sounds like you are looking in a variety of directions. Let's talk, Matt Smith and John Herrick 541-7888-465. matt@smithherrick.com
We would be curious to know about all of the new manufacturing methods you come across. Everyone had great input about the Sliver Removal Device at the meeting, especially the fly fishing version [hehe].
Matt is correct about the cost of Lost Wax Casting. I also designed tooling for aerospace and golf castings, which were expensive, but I have seen some low cost versions done in Asia, if that is where you would ultimately source your end product.
The metal injection sounds intriguing. I did some powdered metal projects for Taylor Made Golf a while ago, which worked great as a passive component, but may not work as well with yours.
I appreciate the comments. Nolton discovered Netshape Technologies is posting a series of informational videos on engineeringtv.com. New installments are released regularly. The current series is about MIM metal injection molding. Some highlights: -a powdered metal is mixed with a powdered plastic(water soluble polymer). -good variety of metals/alloys/stainless. -the metal is expensive but there is no waste. -small parts only, up to 150 grams but better if under 100. -insignificant porosity voids compared to investment casting(whatever that is). -uses standard injection molding machines. -the polymer holds the shape until it is furnaced(sintered). -the parts shrink 20% when the polymer is removed so must be considered at planning and design stage. -minor secondary processes are usually performed to reorient the parts if curves, bends, or warps occur during sintering(the heating of a material to below it's melting point until the particles adhere to each other). -due to densification variation, standard tolerances are + or - .3% -many subsequent processes can be performed like heat treating, etc. This information is somewhat accurate. Feel free to correct, add, or clarify.
Porosity is the inclusion of tiny voids inside the part. Typically they will be below the surface, however if you do secondary operations to the part (drilling, tapping, threading, machining, grinding, etc...) you may expose these voids. Depending on application it could be a bad thing.
Thanks you guys. OK, so.... how insignificant or tiny the voids are is variable and especially relevant if the surface is to be penetrated with secondary processes. I am still wondering what is investment casting.
Yes and the presence of the voids is dependent on the mold design and the complexity of the part. Typically if you imagine metal flowing (better yet water or air) any features that will create severe turbulence such as sharp corners or, features that would create back eddies, will be where you will see the porosity. I had a project where we were seeing severe porosity in aluminum castings, the features that caused is were cast in threads (like in a large screw). The sharp corners and the location where the metal entered the mold caused this phenomenon.