Manufacturing Processes utilized for Design
An advantage of being a small engineering consulting firm is the ability to utilize whatever type of manufacturing processes that a particular project may require, without being restricted to any particular in-house process.
For example, a typical design may very well include machined components, sheet metal components, modified off the shelf components, EDM'd components, etc.
PMD regularly designs using the following manufacturing processes:
Machining
PMD takes advantage of CNC machining as much as possible, in many cases eliminating the need for fully-dimensioned components drawings. (PMD highly prefers to create at least a representative 2D drawing for every fabricated component, including, at a minimum, critical fit dimensions)
Sheet Metal
PMD has pushed the limits of sheet metal design, using CNC punch presses, enabling complex, attractive shapes to be made out of planar and cylindrical sheet metal components, either welded or riveted together, often giving the impression of high-volume stamping without the associated tooling costs.
Rapid Prototyping (3D Printing)
Smaller projects (for example, surgical instruments, small commercial products, etc.) often benefit from Rapid Prototyping. This enables prototypes to be manufactured with no tooling or setup time whatsoever. Parts are fabricated directly from CAD files in a day or two, then FEDex'd to PMD / the customer.
The capabilities of Rapid Prototyping (3D printing) machines and materials are always improving. Typical processes include SLA (Stereolithography), SLS (Stereosintering), and FDM (Finite Deposition Modeling).
Precision Stamping
Precision Stamping / Bending is much like “miniature sheet metal”. Many of the same principles apply.
Injection Molding
EDM'ing
Laser Cutting
Water-Jet Cutting
Vacuum Forming
PMD has established relationships with many types of fabricators, and is constantly learning about the latest manufacturing methods.