Requirement Gathering
Understand client needs and specifications clearly.
- Meet with clients to understand project scope and expectations.
- Document functional and technical requirements.
- Identify constraints, deadlines, and quality standards.
- Create a formal brief to align all stakeholders.
Concept Sketching
Initial layout and design sketches for review.
- Create hand-drawn or digital sketches.
- Design rough layouts including dimensions and sections.
- Discuss initial visuals with the client for approval.
- Revise sketches based on feedback.
CAD Design
Create precise digital models for patterns.
- Use CAD tools like AutoCAD, SolidWorks or Fusion 360.
- Design 2D and 3D models as per the finalized sketch.
- Ensure modeling includes allowances and shrinkage factors.
- Simulate stress or mold flow if needed.
Material Selection
Select appropriate material for durability and use-case.
- Evaluate mechanical, thermal, and chemical requirements.
- Choose from wood, plastic, metal, or composite materials.
- Verify availability and cost-effectiveness.
- Confirm selection with client and internal QA.
Pattern Making
Convert CAD design into physical patterns.
- Use manual or CNC machining for shaping patterns.
- Produce core and cavity sections with high accuracy.
- Incorporate runners, gates, and risers as per design.
- Check tolerances and dimensional integrity.
Inspection
Ensure dimensional accuracy and quality.
- Use vernier, calipers, gauges, and 3D scanners.
- Cross-check measurements with CAD dimensions.
- Perform visual quality checks for cracks or defects.
- Document results in QA reports and logs.
Finishing
Polish and refine the surface and edges.
- Smooth surfaces using sanding, buffing, or coating.
- Deburr sharp edges for safe handling.
- Apply protective coating or color if required.
- Prepare final part for delivery or casting.
Delivery
Pack, label, and handover to client or foundry.
- Use protective foam, shrink-wrap, or boxes.
- Label with project name, part ID, and QR codes.
- Provide test reports, QA checklist, and warranty slips.
- Handover or ship based on client preference.
