INTRODUCTION TO

MANUFACTURING
METHODS

15 August 2022
Manufacturing methods is the process involves in the development,
generation and production of a new component from the simplest
to the most complex method of manufacture in order to achieve the
customer requirement, company policy, regulation and
international standard of quality.

The manufacturing of a new product is a complex process involving

•The development of product specifications
•The generation of a functional design.
•The generation of a production design which involves a study of the
process of adapting component parts to the simplest method of
manufacture. Therefore, it is essential that manufacturing students
understand the principles of manufacturing processes.

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Generally manufacturing methods used in aviation
industry can be divided into 4 types.
a. Manual/ conventional method, example, hand
forming, conventional shop.
b. Semi Automated, example touch numerical
control.
c. Automated. examples; CNC, CMM, CATIA, CAD
CAM, SPC, Robotics.
d. Advance Technology Method. example;
Concurrent engineering, Integrated
Manufacturing and dynamic performance
technology testing.

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• The term shop processes refers to the basic methods
used by the shop to make the object described in the
engineering drawing.

• The specific processes used to make the object depend

on the object itself. In some cases the part may be cast,
while other parts may be forged, extruded, or
stamped. In many instances the part, once fabricated
into its basic form must also be machined to maintain
a specific degree of accuracy or to produce a feature
not possible with other manufacturing processes.

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• When the shop receives the engineering drawing, in the
form of a part print, it is first reviewed to ensure all
pertinent data and information necessary to make the object
are contained in the drawing.
• During the review, the shop personnel will consider several
factors necessary to determine how the part must be made.
These factors include:
 The type and condition of the material used to make the
object,
 The lead time required
 The overall size and shape of the part,
 The types of operations required, and
 The required accuracy of the part, and
 The number of part to be made.
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• The type and condition of the material used to make the part
are important considerations. Some parts may be made from
solid bar stock while other parts must be extruded, cast,
forged, or stamped. In most cases, parts made from bar
stock require the least lead time.
• The lead time is the interval from the time the shop receives
the drawing until production begins. Most shops maintain a
sufficient supply of bar stock to begin production as soon as
the drawing is received. However, when a part must be
extruded, cast, forged, or stamped a longer lead time is
required to make the necessary molds or dies to fabricate
the object.
• Lead time - The amount of time between the placing of an
order and the receipt of the goods ordered.

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• The size and shape of the object must be considered to
determine if the object is within the capabilities of the shop
to make. In addition, the size and shape may also determine
the size of the machine tools required as well as the datum,
or reference surfaces used to locate the part during
manufacture.
• The types of operations required determine the types of
equipment and machine tools needed to make the part. If,
for example, the part requires holes, a drill press, vertical
milling machine, or other machine tool may be used.

• The next consideration, the required accuracy of the part,

also determines how the operations are performed. A hole
with a required accuracy of .002''(0.05 mm), for example,
would require reaming, while a hole with a required accuracy
of .02011(0.5 mm) could be drilled.
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• The number of parts to be made will frequently determine if
the part should be cast, forged, extruded, or machined from
solid stock.
• The number of parts will also determine if any special work
holders (jig & fixtures) are to be made.
• Larger production runs will normally justify more
sophisticated tools and processes since the cost can be
spread over a larger number of parts.
• Smaller production runs normally demand the parts to be
made at the lowest possible cost with little or no investment
in special molds, dies, or work holders.
• The primary processes used to fabricate manufactured
products are casting, rolling, forging, extruding, stamping,
and machining. To use these processes to their best
advantage, the designer must be familiar with the strengths
and weaknesses of each process as well as the fundamental
aspects of each process. 8
Aerospace industry:
•Manufacture and assembly of aircraft
•Manufacture of aircraft equipment, components,
accessories or parts thereof
•Ground support equipment for the aerospace industry
•Maintenance, repair, overhaul or service of aircraft,
aircraft components or accessories or testing and
repairing of avionics

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Aircraft components
• Airframe Structural Parts and
Components.
• Aircraft Systems, Sub Systems
and Components; and 
• Aircraft Engine Casing

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