Metal is the backbone of modern industry - from the cars we drive and the tools we use, to the skyscrapers that define our skylines. Over centuries, metal manufacturing has evolved into a sophisticated field of engineering - one that transforms raw materials into durable, functional, and beautifully crafted products.

Whether you're developing a new product or optimizing production, understanding the most common metal manufacturing methods helps choose the right process for your design, performance, and budget.

Here are 4 of the most commonly used manufacturing processes for metals :

1. CASTING : Casting is one of the oldest and most versatile manufacturing processes. It involves pouring molten metal into a mold cavity that defines the desired shape. Once the metal cools and solidifies, the mold is removed, revealing the finished part.

   
   

   

   
   

   There are several types of casting methods - such as sand casting, die casting, and investment casting - each suited to different metals, geometries, and production volumes. Common applications include engine blocks, heavy machinery, industrial components (e.g., bearings, valves, and fittings), metal sculptures, and complex parts that require internal cavities and intricate detailing.

   
   

   

   
   

   A controversial citrus juicer made of cast and polished aluminum. Mold shown on right.

   
   

2. MACHINING : Machining is a subtractive manufacturing process in which material is removed from a solid metal block (known as a billet) to achieve the desired shape. This is typically done using tools like lathes, mills, drills, or CNC machines.

   
   

   Machining offers exceptional precision and surface finish, making it ideal for components that require tight tolerances or complex geometries. The list of commonly machined parts are endless so we won't list them here, however if you're curious to see a machining example in action, here's a video showing how Apple CNC machines Macbook casings : https://www.youtube.com/watch?v=oEaW4tQ-9aM

   
   

   

   
   

   Close-up of milling on a CNC lathe

   
   

3. METAL FORMING : Metal forming encompasses processes that uses force to shape metal without adding or removing material. Common techniques include forging, rolling, stamping, bending, and extrusion.

   
   

   Each method offers different advantages, depending on the metal type, desired strength, and production volume.

   
   

   For instance, forging produces extremely strong components like crankshafts and wrenches, while extrusion is used for creating long, continuous shapes such as rods, tubes, and rails.

   
   

   Each forming techniques deserves it's own article, which we hope to cover in the future, however below are a few examples :

   
   

   Here's a YouTube short of a CNC tube bender for those that are curious - https://www.youtube.com/shorts/Lcsi2avIaLQ?feature=share

   
   

   

   
   

   Close-up of bending sheet metal on a press brake

   
   

   

   
   

   Automotive panels are typically stamped or hydroformed. Watch this short video to see how it's done - https://www.youtube.com/shorts/pY1CV2uHdI4?feature=share

   
   

4. WELDING AND FABRICATION : Welding joins two or more metal pieces by melting their edges and fusing them together - often with the addition of a filler material. Fabrication combines cutting, bending, and assembling processes to create complete metal structures or products. Common welding methods include MIG, TIG, and ARC welding each chosen based on material type and application.

   
   

   

   
   

   TIG welding

TL ; DR

A wide range of metal manufacturing processes exist to meet different design and performance requirements. Casting, machining, metal forming, welding, and sheet metal forming are among the most common - each offering unique advantages, limitations, and opportunities depending on your project's needs.

If you're developing a metal product or component, Axam Design can help you navigate the complexities of design and manufacturing. We'll ensure your product not only looks and functions great, but is engineered for performance, durability, and production efficiency.

Don't hesitate to contact us today to start transforming your ideas into reality.