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Nearly net-form manufacturing aims to produce components as close to their finished state as possible, reducing waste and increasing efficiency. This process can be used in metalworking, ceramics, and thermoplastics but requires an overhaul of the production process and investment in new equipment. The benefits include reduced costs and improved quality control.
Factories seeking to maximize efficiency and keep costs low may choose a nearly net-form manufacturing strategy. Based on a nearly net form plan, the manufacturer aims to produce components that are as close to their finished state as possible. For example, a company that makes solid metal fasteners will streamline manufacturing to complete the fastener in as few steps as possible. Rather than starting with a solid block of metal and using grinding and milling techniques to form and shape the fastener, the factory will likely create a mold to cast the finished product in one step.
Neighboring network shape production can be applied to a wide variety of media. It is often used in metalworking, especially with titanium and other expensive alloys. This process can also be used in the production of ceramics, where spray or gel ceramics can offer an almost clean-cut alternative to milling or machining. This type of production plan can also be applied to the production of thermoplastic materials, where injection molding can replace more traditional production methods.
A factory wishing to instill an almost net form system may be required to overhaul the entire production process. Rather than an assembly line process, net near requires the combination of many processes into one step. This can significantly speed up the production process and increase production rates in the long run.
One of the major benefits of producing near-net shapes is the way it encourages efficient use of material. Instead of slowly creating a widget from a solid block of material, the company uses exactly the right amount of material to cast the widget into a mold or die. This process reduces waste, reduces energy consumption and keeps costs down. It also reduces the total number of machines and tools needed to complete the process and can reduce labor costs for some products.
Near Net Shape strategies also help companies create a near-perfect product. By using a mold, companies eliminate errors and produce consistent finished products. This strategy helps improve quality control throughout the company.
This process is also associated with a number of disadvantages which should be considered before implementing near net shape plans. Near net often requires factories to invest in all new equipment, which can lead to high initial costs. This includes new metal molds or dies as well as new tools and employee training. While this strategy often pays off in the form of lower long-term costs, the high initial investment can make it nearly out of reach for some companies.
