Reliable Mass Production Services for High-Precision Parts

What are the benefits of mass production?

There are many benefits to mass production of machined parts:

Higher efficiency

Mass production is much better than low volume orders or small batches in terms of efficiency and generating as little waste as possible.

Lower costs

Mass production orders typically have a lower cost per item since the materials can be ordered in bulk, and the manufacturing line is set up once. That means that in the end, a single item will have a much lower price than the same item in a low-volume order.

Better accuracy

And, naturally, mass production results in increased accuracy and consistency of the parts’ geometries, shapes, and other properties. Each item will be identical to the rest since they will use the same program on our machines.

What are the disadvantages of mass production?

Here are some of the cons or disadvantages of mass production of metal or plastic parts:

Higher starting costs

Mass production requires higher initial costs since you’re ordering in bulk. However, our clients find worth in this since they save a lot in the long run. We already mentioned that the bulk price per single item is always lower than in small batches. So, by ordering in bulk, our clients actually save in the long run.

Lack of flexibility

The last disadvantage you have to consider before choosing mass production is the lack of flexibility. In CNC machining, we program and set up the project specifications once, and the entire batch will have those features. Making changes can be difficult once manufacturing has started.

However, with our cutting-edge 3D printing, flexibility is still possible, even in bulk orders.

When should I choose mass production?

Our clients typically choose our mass production services when bulk parts are needed for their secondary manufacturing processes or when they already have a placement for their product.

A high-volume order is more efficient and gives you maximum accuracy since the machines are programmed once, guaranteeing the production of identical parts. Due to the reduced manufacturing complexity in mass production and reduced material sourcing prices, you’ll enjoy a reduced price per item.

Before mass production, what stages will the product go through?

The life cycle of a product (in this case, a part) typically goes through several stages, culminating in mass production as a final stage. Here’s what it takes to get from an idea to mass manufacturing:

Initial concept and market fit

At the first stage, you conceive the product idea and research its market fit. Then, you typically form an idea or a concept of the functionality and appearance of your product. You estimate your monthly/yearly needs and the costs related to the eventual mass production of the needed parts.

Product design

At this stage, you start designing the part and create a sample using CAD or 3D models. Product design can be divided into three sub-categories:

• Functional design – to ensure that the part does its job correctly and can be used for its intent;
• Mechanical design – to make sure the product’s strength, safety, and resistance fit the requirements;
• Appearance design – to make the product shape, geometry, and surface finishing as perfect and accurate as possible;

Prototype

Once you pass the design stage, it’s time to build your first prototype. You can choose an on-demand manufacturer like DEK to design, customize, and manufacture your prototype from any material you need.

DEK offers the most advanced CNC machining, 3D printing, and vacuum casting technologies, resulting in the most rapid prototyping service on the market.

Small volume manufacturing

Once your prototype is done, you can analyze its design and usability, make any changes needed, and order your first small batch. A flexible and reliable manufacturer like DEK can help you a lot with this since we adjust to everyone’s needs – we do prototypes, low volume, and mass production orders.

What are the main technologies for plastic parts mass production?

Plastic injection molding

With plastic injection molding, we literally inject molten materials like thermoplastics into molds. Plastic injection molding is a cost-effective way to manufacture identical parts in bulk, so it’s the perfect process for the mass production of plastic parts.

We often use injection molding for automotive parts, toys, bottle caps, and even compact pocket combs. Plastic injection molding can be used for small or large parts.

CNC machining

With the help of 3-axis, 4-axis, and 5-axis CNC machining, you can get high precision plastic parts made of many different materials like Acrylic, ABS, Polycarbonate, Nylon 6/6, Polypropylene, PEEK, and more.

We typically use CNC machining when you need mass production of high-precision parts with tight tolerances.

What are the main technologies for metal parts mass production?

There are seven main technologies for mass manufacturing of metal parts:

CNC Machining

CNC machining of metal parts is used when you need high accuracy parts with tight tolerances manufactured quickly. CNC machining leaves no space for human error and can help you get the most complex forms and geometries to perfection.

With the help of 3-axis, 4-axis, and 5-axis machines, you can bring every metal piece to perfection by using any metal alloys you need. In DEK, we work with a wide variety of metals such as aluminum, stainless steel, titanium, tool steel, and any other material on demand of our clients.

Die Casting

Die casting is a cost-efficient way to mass-produce larger metal parts or products such as containers, gas engine chambers, and similar. For mass production of oversized items, die casting is a much simpler and affordable way to go.

On the other hand, if you need smaller parts with complex geometries and intricate details, die casting probably isn’t the right technology for your needs.

Metal Stamping

We use metal stamping machines when we want to produce certain parts in high volumes. Depending on the part needed, you can choose between three different types of metal stamping: progressive die metal stampings (most common), deep drawn metal stampings, or multi-slide metal stampings.

With metal stamping, you can create different bicycle parts, aerospace and automotive parts, and more.

Metal injection molding

Metal injection molding is different from die casting because it produces smaller parts with more complex designs at a higher volume. With the help of MIM, we can create complex parts in a single step. As a technology, metal injection molding is used when we need a high tensile strength of the finished parts.

Aluminum extrusion

With aluminum extrusion technology, we can transform aluminum alloys into thousands of different parts used in electronics, telecommunication, automotive, bridge decking, and other industries.

Aluminum extrusion can help you create various cross-sectional profiles of your parts by simply pushing the heated aluminum alloy through the appropriate die. Like this, you can get solid, semi-hollow, or hollow parts for your needs.

Fiber laser cutting

Fiber lasers have different wavelengths, which allow us to perform precise cutting of metal parts. We use fiber laser cutting when we have the tiniest and most complex geometries that are impossible to achieve otherwise.

The fiber laser cutting technology is used for producing delicate parts in the automotive industry, healthcare and medical, jewelry, etc.

Forging

Forging is a metal part manufacturing technology most commonly used in engine and transmission parts, but its applications can be used in many industries. For instance, we can use forging to create parts for aerospace, automotive, electricity generation or transmission, power tools, and more.

Our clients typically choose forging mass production when they need parts with extraordinary strength and heat resistance.

Is 3D printing suitable for mass manufacturing?

Contrary to popular belief, 3D printing plays a significant role in mass manufacturing. The advantages of 3D printing are countless. Firstly, 3D printing is a much more flexible technology, and it’s easier to make changes or corrections in the production line.

Secondly, 3D printing has no limitations on geometry or shape complexity. And thirdly, it can be used with many different materials and produce tiny details that are impossible to get otherwise.

Which mass production technology is right for your project?

Choosing the right mass production technology depends on many different things:

• Do you need plastic or metal parts?
• How complex is your part’s design or shape?
• What’s the size of your part?
• What’s the purpose for the part (some parts that are used in engines need a higher temperature resistance, thus a different production technology)?

If you aren’t sure what technology you need, you can request a quote for free, and we will help you decide based on your project specifications.

What are the things to pay attention to in mass production?

In mass production of machined parts, we have to be careful of:

• Proper programming of machines;
• Assembling an efficient production process;
• Accuracy and consistency of the parts;
• Timeline or turnaround time;
• A good quality control process;
• Achieving the tight tolerances needed;
• Safety and durability of the produced end-parts;

Does DEK provide mass production services?

Yes! DEK is a leading on-demand manufacturer, and we provide mass production of plastic and metal parts in any quantities. We adjust to clients’ needs and can manufacture parts in many industries with the highest accuracy, quality, and turnaround time.

All you need to do is prepare your CAD or 3D model and upload them when you submit a quote, and we’ll get back to you in as little as 6 hours.

Does DEK provide surface treatment services for mass-produced parts?

Yes, we do. Often, the end parts will need specific properties that cannot be achieved through the initial machining process. In cases like these, we use different surface finishings and coatings to get the result and features we need.

Does DEK provide assembly services after mass production?

Yes! DEK provides part assembly as part of our on-demand services. After we produce your bulk order, we can set up and customize your assembly line and deliver your ready end parts with a fast turnaround.

Our services come with an included CMM inspection and quality testing of all your assembled products.

Why choose DEK?

DEK is a leading on-demand manufacturer with advanced technologies and capabilities, including high-tech CNC machining, 3D printing, injection molding, die casting, fiber laser cutting, and more. Here’s why DEK is the best partner for your mass production:

• Endless customization possibilities;
• Many years of experience on the market;
• Parts for all industries – aerospace, automotive, healthcare, robotics, construction, and more;
• Cutting-edge CNC machines and technologies;
• No space for human error;
• No MOQs – DEK produces prototypes, low volume, and high volume orders on demand;
• Efficient and automated manufacturing – 40% shorter delivery time when compared to competitors;
• Cost-efficient and affordable – high-quality parts at a price that’s 60 to 80% lower than other factories – due to their streamlined manufacturing processes;
• Any type of material available;
• Thorough quality control and inspection process;

How will DEK ship the products to me?

We take care of the shipping depending on the quantity of the parts you’ve ordered. For small quantities, we recommend express options such as DHL, UPS, or FedEx. Airfreight is a cheap and fast shipping option.

On the other hand, if we’re talking about mass production and bulk orders, or for heavy items, we recommend shipping by sea as a more affordable option.

With DEK, you don’t need to worry about anything! We have a professional logistics supply chain and rich transportation experience, and can even assist in customs clearance to deliver the goods directly to your doorstep.

How to order?

We know your time is precious, so we don’t want to waste it. That’s why we’ve built an efficient way for you to get a quick quote and decide if we’re a match!

All you need to do is have your 3D or CAD model ready and upload it to our website. Describe your project and submit your quote request.

We’ll take a look at your project right away and get back to you with a quote within a maximum of 6 hours! We strive to be as quick as possible and as accurate as possible with our quotes, and we work completely transparently throughout the entire manufacturing process.

As a result, your mass production order will be fulfilled with the highest quality and the fastest possible turnaround time.