| 1 | Application and requirement definition | Confirm the part’s function, loads, operating temperature, environment, service life, and applicable industry requirements before selecting a process. | Product specifications; engineering drawings; functional and environmental requirements | Clear requirements guide material selection, tolerances, inspection plans, and production methods. |
| 2 | Aluminum alloy selection | Compare strength, machinability, corrosion resistance, formability, weldability, and availability for the intended application. | 6061 is commonly used for machined structural parts; 5052 is commonly used for formed sheet parts; 7075 is used where high strength is required. | Alloy and temper affect mechanical properties, machining behavior, finishing response, and cost. |
| 3 | Design for CNC machining | Consider tool access, internal corner radii, wall thickness, clamping surfaces, chip removal, and the number of setups. | CNC milling; CNC turning; drilling; tapping | Accessible features and practical radii can reduce machining time and help avoid tool interference or vibration. |
| 4 | Design for sheet-metal fabrication | Specify bend direction, inside bend radius, hole-to-bend spacing, reliefs, and flat-pattern requirements. | Laser cutting; punching; press-brake bending; sheet grades such as 5052 | Accounting for bend allowance and material behavior helps parts meet dimensional and assembly requirements. |
| 5 | Design for casting | Review draft angles, wall transitions, parting lines, fillets, and machining allowances on critical surfaces. | High-pressure die casting; gravity casting; permanent-mold casting | Castability features support metal flow, mold release, and more consistent production; critical dimensions may require secondary machining. |
| 6 | Tolerance and datum planning | Apply tighter tolerances only to features that affect fit, function, or measurement; define datums and geometric controls where needed. | Engineering drawings; GD&T; coordinate measuring machines | Realistic tolerances improve manufacturability and inspection clarity. Achievable limits depend on geometry, alloy, process, and part size. |
| 7 | Joining and assembly | Assess joint strength, distortion, access, sealing needs, and compatibility with the selected alloy and finish. | TIG or MIG welding; mechanical fastening; inserts; adhesive bonding | Joining choices can affect strength, appearance, heat distortion, corrosion behavior, and the need for post-process machining. |
| 8 | Surface finishing | Specify appearance, corrosion protection, wear resistance, surface texture, and masking requirements. | Anodizing; chemical conversion coating; powder coating; mechanical polishing | Finishes serve different purposes and may change dimensions, surface properties, or the appearance of the alloy. |
| 9 | Quality inspection | Set inspection methods and acceptance criteria for dimensions, surface condition, material, and functional features. | Calipers; micrometers; height gauges; CMM inspection; material certificates where specified | A defined control plan links drawing requirements to repeatable measurements throughout production. |
| 10 | Supplier and production capability review | Review relevant process experience, equipment capability, traceability, documentation, sample approval, and change control. | Process capability records; first-article inspection; production samples; inspection reports | Evaluating evidence against the part’s requirements is more useful than relying on a general ranking or a single machine specification. |