The Overall Process of Gunmaking

In many of our posts in the last three years, we've studied processes of manufacturing different
components of a firearm. It is time to now look at how the entire process works from start to
finish.

There are a few basic processes that are essential to making firearms:

1. Forging - This is used to make the majority of iron and steel parts.
2. Casting - This process is often used to make small parts, especially those of complicated
shapes.
3. Machining - This is a process that uses machine tools to finish parts that were made using
forging and casting processes. Rifling is also made by machining processes.
4. Stamping - This is a more modern technology and is used to make parts out of sheet metal,
e.g. trigger guards, parts of sights etc.
5. Woodworking - Used to shape stocks for firearms from raw wooden blanks. In modern days,
stocks are also built of other materials, so this is no longer as important as some of the
other processes above.
6. Metal treatments - There are many types of metal treatments. Applying protective coatings
to various components, rust proofing, heat treatment hardening of certain components etc.
all fall under this category.
7. Assembly - Taking all the components and putting them together to build the firearm.
8. Testing - All reputable manufacturers perform testing of their products to make sure that
they are reliable and can withstand normal usage. In some countries, proof testing is
mandatory by law.

Forging
This is one of the older iron working processes known to man. It was used by ancient blacksmiths
and the same principles apply to the present day, even if the tools used are different. Iron and
steel pieces are heated to red-hot temperatures, at which point they become soft and easier to
shape. The red-hot pieces are then hammered into the shape of the finished components and then
cooled down. In many cases, a specially shaped die is used and the red-hot pieces are placed into
the die and hammered to their final shape. One of the advantages of the forging process is that it
compacts the metal and makes it stronger.

These days, we have large forging machines that can hammer out larger components, such as
receivers and barrels of rifles easily.

Casting
Casting is a process where a mold of a desired shape is initially prepared, then molten metal is
poured into the mold and allowed to solidify. Casting is also an ancient metalworking processes and
has been used in history to make intricate shapes as well as large objects. While a cast metal part
is not as strong as its forged equivalent, it is often used to make complicated shapes which would
be uneconomical to make with any other technique. One more advantage of casting is that many
parts may be cast at the same time.

On the flip side, cast parts may have microscopic cracks and flaws due to factors such as uneven
cooling, lack of proper venting etc.

Machining
After a part is forged or cast, it is usually close to the required dimensions, but not precisely so. It
may also have tiny burrs and surface imperfections on it. This is where the task of machining comes
in: to size the part to the proper dimensions and polish it as needed. Machining the parts to greater
precision also makes parts interchangeable. Machining is also needed to cut rifling in the barrel.

There are various machining operations: cutting, turning, drilling, polishing, grinding etc. and there
are specialized machines to perform each task.
Stamping
Stamping is the process of cutting and shaping parts out of sheet metal. Unlike forging, stamping is
usually done to cold metal. Stamping is typically used for parts that don't take as much heavy load,
for instance, a trigger guard or a magazine. With modern technological improvements, stampings
can be used to also manufacture upper and lower receiver parts for some submachine guns and
battle rifles.

Stamping is also used to put serial numbers on various parts of a rifle.

Woodworking
Back in the days when stocks were made of woods such as walnut, beech, ash, myrtle etc., the art
of woodworking was used heavily in the gun trade. A skilled woodworker would take a block of
wood and using various tools such as lathes, chisels, planers etc., would carve out gun stocks, to
which the barrel and firing action were fitted. On more expensive models, craftsmen would
engrave patterns, cross-hatches, inlay precious metals etc. into the stocks.

These days, stocks are made of other materials as well (e.g.) plastic, fiberglass composite, metal
etc., where woodworking skills are not as important. However, some of the finest shotguns and
rifles still feature wooden stocks carved by very skilled craftsmen.

Metal Treatments
The various metal parts of the firearm may be treated via chemical processes, to add a thin coating
that prevents rust and also may be wear-resistant. Some parts may also be hardened after
machining, so that they can bear the stresses of normal usage better. We studied many of these
treatments earlier e.g. case hardening, bluing, parkerizing, tenifer, melonite etc.

Assembly
After the parts of the firearm are manufactured, they still need to be put together to make a
functional firearm. The process of putting the parts together may involve tasks such as riveting,
welding, gluing, tightening screw threads, lubricating etc.

Testing
After the parts are put together, the firearm needs to be tested to make sure that it is functioning
accurately and reliably. In some countries, there are standard tests that are enforced by the
Government and any firearm marketed in these countries is required to pass the standard tests
before it can be sold. All reputable manufacturers also run various tests during various stages of the
manufacturing process, to catch any problems as soon as possible.
Posted by The Editor at 11:56 PM

The purpose of a gun–if we're being honest–is to kill something. It's a tool that has enough
power, when used properly (and very often improperly) to kill. Hunting rifles and shotguns
are for killing animals
A Look at Gun Materials and
Production
Most firearms are made of steel, aluminum or plastic, or a combination of metal and
plastic. Each material has natural attributes that benefit effective gun construction,
including aesthetic, weight and strength. Some materials are preferable to others,
specifically for their strength. In gun production, experts apply directional force to
stress test the composite strength of a given material.

To evaluate the maximum force a material can withstand without permanent

damage, manufacturers apply compressive force, torsional strength, and tensile
strength. Gun manufacturing and testing is a precise, complex process involving
careful engineering, specialized metal alloys, and extensive testing to produce a
reliable gun. Let’s take a closer look at three standard gun materials and how they
affect gun performance.

STEEL GUN CONSTRUCTION

Steel is the foundational material in any gun. Traditionally, gun production uses high-
carbon, heat-treated steel. The heat treatment scale is quantified by the Rockwell C
scale. Compression and tensile strength are important factors to test in steel
construction. Recoil in the gun is absorbed by the recoil plate as force is applied to
that part of the frame.

Modern steel gun construction is more efficient and cost-effective when

manufactured by computerized machining centers. Because steel is so strong and
versatile, it can be manipulated easily into structures and small parts using castings
and machine injection molding. The weight of steel makes control and aim steadier
and more efficient—but also heavier. Steel is easily finished with stainless finish
alloys, nickel, and chrome plating. This makes the final gun corrosion resistant and
adds a nice aesthetic.

ALUMINUM GUN CONSTRUCTION

Aluminum framing is one of the most important components in modern guns and can
save 35–40% in weight compared to steel. However, aluminum-framed guns are not
as durable as steel and lack steel’s tensile strength. Therefore, proper aluminum
alloy selection must consider weight balance and grip width for effective ergonomics.

Aluminum is a popular alternative to steel for certain guns—certain 9mm pistols, for
example—and offers a lightweight, aesthetic look and feel. Lower compression and
tensile strength make aluminum frames more susceptible to stress cracking. When
this occurs, repairs are unlikely. The recoil can also be greater in aluminum framed
guns.

PLASTIC GUN CONSTRUCTION

Polymer plastics were originally used in gun production on non-structural
components such as recoil spring guides and grips. Eventually, plastic was used in
small gun components and as part of the frame. Many guns today employ polymers
in frame production as popular alternatives to traditional steel. Plastic has several
benefits, including its lightweight nature and damage resistance from recoil impact.
Unlike steel, plastic is more comfortable in a wider temperature range. Plastic frames
also allow a certain versatility in interchangeable grip panels for different hand sizes.

Unlike aluminum and steel, however, plastic has low tensile strength and can more
easily fail compared to denser, more resistant metals. Its lighter weight can also
compromise aim stability and recoil control, but these depend on the shooter and the
specific type of gun. Overall, plastic construction is often cheaper and offers weight
savings and corrosion resistance.