Success in metal component manufacturing depends on pairing the right alloy with the most accurate and cost-effective production process. Selecting an unsuitable process can multiply unit costs by 3x to 5x.
Four Core Criteria in Process Selection
- Batch Volume & Lot Size: For prototypes, custom parts, and low-to-medium production runs, CNC machining from solid billet eliminates expensive mold/die amortization. For very high volumes, near-net forging or casting followed by CNC finish machining is preferred.
- Geometric Complexity: Intersecting internal manifolds, undercut pockets, and compound-angle ports require 5-axis CNC milling.
- Tolerance & Surface Roughness: Sand/die casting or metal 3D printing cannot directly achieve H6/H7 bearing fits or Ra 0.4 µm sealing faces—precision CNC machining is always required for critical mating surfaces.
- Material Grade & Hardness: Heat-treated alloy steels, titanium, and aerospace 7075 aluminum achieve superior mechanical integrity when machined from wrought certified bar or plate stock.