Manufacturing Process Selection Handbook provides engineers and designers with process knowledge and the essential technological and cost data to guide the selection of manufacturing processes early in the product development cycle.

Building on content from the authors’ earlier introductory Process Selection guide, this expanded handbook begins with the challenges and benefits of identifying manufacturing processes in the design phase and appropriate strategies for process selection. The bulk of the book is then dedicated to concise coverage of different manufacturing processes, providing a quick reference guide for easy comparison and informed decision making.

For each process examined, the book considers key factors driving selection decisions, including:

  • Basic process descriptions with simple diagrams to illustrate
  • Notes on material suitability
  • Notes on available process variations
  • Economic considerations such as costs and production rates
  • Typical applications and product examples
  • Notes on design aspects and quality issues

Providing a quick and effective reference for the informed selection of manufacturing processes with suitable characteristics and capabilities, Manufacturing Process Selection Handbook is intended to quickly develop or refresh your experience of selecting optimal processes and costing design alternatives in the context of concurrent engineering. It is an ideal reference for those working in mechanical design across a variety of industries and a valuable learning resource for advanced students undertaking design modules and projects as part of broader engineering programs.

Key Features

  • Provides manufacturing process information maps (PRIMAs) provide detailed information on the characteristics and capabilities of 65 processes in a standard format
  • Includes process capability charts detailing the processing tolerance ranges for key material types
  • Offers detailed methods for estimating costs, both at the component and assembly level


Professional engineers involved in mechanical design and manufacture, including those working within automotive, aerospace and related mechanical industries; Advanced students and graduates undertaking modules in design and manufacture as part of mechanical, automotive and aerospace degree programs

Table of Contents




List of Terms


Abbreviations – General

Abbreviations – Manufacturing Processes

Manufacturing Process Key (for Chapter 12)

Materials Key (for Plastics Processing)

Chapter 1. Introduction to the Handbook

1.1 The Economic Case for Manufacturing Process Selection

1.2 Manufacturing Process Information for Designers

1.3 This Handbook, its Objectives and Strategy


Chapter 2. Process Selection Strategies and Case Studies

2.1 Manufacturing Process Selection

2.2 Rapid Prototyping Process Selection

2.3 Surface Engineering Process Selection

2.4 Assembly System Selection

2.5 Joining Process Selection


Chapter 3. Casting Processes

3.1 Sand Casting

3.2 Shell Moulding

3.3 Gravity Die Casting

3.4 Pressure Die Casting

3.5 Centrifugal Casting

3.6 Investment Casting

3.7 Ceramic Mould Casting

3.8 Plaster Mould Casting

3.9 Squeeze Casting

Chapter 4. Forming Processes

4.1 Forging

4.2 Rolling

4.3 Drawing

4.4 Cold Forming

4.5 Cold Heading

4.6 Swaging

4.7 Superplastic Forming

4.8 Sheet-metal Shearing

4.9 Sheet-metal Forming

4.10 Spinning

4.11 Powder Metallurgy

4.12 Metal Injection Moulding

4.13 Continuous Extrusion (Metals)

Chapter 5. Plastics and Composites Processing

5.1 Injection Moulding

5.2 Reaction Injection Moulding

5.3 Compression Moulding

5.4 Resin Transfer Moulding

5.5 Vacuum Forming

5.6 Blow Moulding

5.7 Rotational Moulding

5.8 Contact Moulding

5.9 Pultrusion

5.10 Continuous Extrusion (Plastics)

Chapter 6. Machining Processes

6.1 Turning and Boring



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© 2013
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