The cost of manufacturing metal is inexorably linked to its quality. Each project's budget must accommodate specific industry standards and design elements, and the final product must be cost-effective and valuable for its intended purpose. As with most manufacturing processes, several factors can affect the price and quality of the final product. Understanding these variables can help you determine the best approach. This article will explore what manufacturers should know about metal fabrication costs and quality control.
Manufacturing experts define quality
A quality assessment is subject to multiple considerations, even in precision manufacturing. The designer determines whether the final product is in line with the initial concept and must observe industry standards to ensure compliance with ISO standards and consumer expectations. However, this is only part of a comprehensive quality control system.
Engineers and machining teams must make a series of decisions to ensure safe and accurate metal fabrication. Your choices can increase or decrease the quality and usability of a piece. Many factory shops utilize various quality assurance tools to check and double-check their work. This may require more time and money, but industry standards may require it.
Manufacturers define quality based on whether a manufactured metal part meets or exceeds these standards. Parts that are not up to par can be discarded or removed for reuse of materials. However, other processes and extended delivery times may affect your price. Talk to your team for more specific information or a personalized plan.
Quality control measures affect manufacturing costs
Achieving high-quality metal fabrication requires a worthwhile investment – a concept that is well understood by manufacturers who prioritize excellence. However, you can still save money by understanding the factors that affect costs.
Tighter tolerances can mean more costs.
The cost of metal fabrication depends significantly on the required tolerances. For example, consider a metal disk with specific diameters and a hole. If the hole tolerance is ±0.030″, a 2D laser can cut it efficiently. However, if the tolerance is smaller, say ±0.001″ or ±0.002″, the hole must be drilled, necessitating an additional deburring operation. Each added step exponentially increases the cost of manufacturing, illustrating how tighter tolerances can increase expenses.
Some raw materials cost more than others.
Expect to pay more for rare materials or high-quality parts that are difficult to manufacture. Some suppliers may also charge extra for metal products that require international shipping or initial processing. Supply chain disruptions are unpredictable and beyond the store's control, so budget accordingly.
A complex manufacturing process can be expensive.
Engineered metals make the world go round. They also invite innovation and require advanced machining techniques to manufacture complex designs. However, complicated geometries and tight tolerances can be expensive. Sophisticated manufacturing processes utilize integrated quality control systems to speed results, but the software and tools required can go beyond a small budget.
Industry standards may require improved manufacturing.
A project may involve multiple iterations, depending on industry quality standards. Meanwhile, companies that have an ISO-certified quality management system may require modifications to some design elements. Restarting the manufacturing process is not cost-effective, so many teams use rapid prototyping to evaluate and troubleshoot parts. When you use an experienced fabrication shop, advanced metal fabrication can be cheaper despite these factors.
Finishing adds costs.
If your project requires additional metal finishing, expect a higher bill. Your costs will also increase if you order assembly, inspection, or mass production after initial manufacturing.
4 ways to reduce costs while maintaining quality in metal manufacturing
High-quality manufacturing requires flexibility and an experienced team. It also takes a smart approach that employs economical metal fabrication techniques. Use these tips to save money without sacrificing the quality of your final product:
- Use an appropriate quality control system— Develop a quality control system that supports your project goals and tailor inspections to meet applicable industry standards.
- Choose abundant raw materials – Avoid manufacturing hard-to-find metals. Discuss possible alternatives with your engineering team.
- Start with simple designs – Save the complex geometries for when you have more time or capital. Start with simple iterations and build from there.
- Consider rapid prototyping – Additive layer manufacturing (which includes 3D printing) can be used to simulate metal parts, allowing you to verify design elements, eliminate unnecessary waste, and speed production. Digital manufacturing techniques may require an additional upfront fee, but these processes can pay for themselves over time.
Several factors can influence the cost of metal manufacturing. When you understand how different variables affect pricing, you can get the best final products at the lowest possible cost. Discuss the details with your team, make sure your project aligns with industry standards, and calculate a budget.
