Manufacturing processes, dimensional ranges and materials
Tolcap covered manufacturing processes with corresponding dimension ranges, tolerance ranges, and were applicable materials.
| Process Group |
Manufacturing Process | Dimension Range |
Tolerance Range |
Materials |
|---|---|---|---|---|
| Casting | Centrifugal casting - all metals | 10-1500mm | 0.01-5mm | |
| Ceramic mould casting - all metals | 1-1000mm | 0.01-5mm | ||
| Gravity die casting for aluminium and magnesium alloys | 1-1000mm | 0.01-5mm | ||
| Gravity die casting for iron and copper alloys | 1-1000mm | 0.01-10mm | ||
| Investment casting - all metals | 1-700mm | 0.01-4mm | ||
| Plaster mould casting for aluminium and magnesium alloys | 1-500mm | 0.02-2mm | ||
| Plaster mould casting for zinc and copper alloys | 1-500mm | 0.02-2mm | ||
| Pressure die casting for aluminium and magnesium alloys | 1-1000mm | 0.01-10mm | ||
| Pressure die casting for copper alloys | 1-500mm | 0.01-10mm | ||
| Pressure die casting for zinc alloys | 1-1000mm | 0.01-10mm | ||
| Sand casting for aluminium and magnesium alloys | 10-5000mm | 0.1-30mm | ||
| Sand casting for copper alloys | 10-5000mm | 0.1-30mm | ||
| Sand casting for steel and iron | 10-10000mm | 0.3-50mm | ||
| Shell moulding for aluminium and magnesium alloys | 10-1000mm | 0.1-10mm | ||
| Shell moulding for steel, iron and copper alloys | 10-1000mm | 0.1-10mm | ||
| Cold drawing and rolling | Cold drawing for copper and copper alloys | 1-100mm | 0.01-0.5mm | |
| Cold drawing for low to medium carbon steels | 1-150mm | 0.005-0.5mm | ||
| Cold rolling for aluminium alloys | 0.1-100mm | 0.005-2mm | ||
| Cold rolling for copper and copper alloys | 0.1-100mm | 0.001-1mm | ||
| Cold rolling for low to medium carbon and low alloy steels | 0.1-100mm | 0.001-1mm | ||
| Cold forming | Cold forming and finishing - radial tolerance only | 1-100mm | 0.005-0.2mm | Steels - Alloy |
| Steels - High Carbon | ||||
| Steels - Medium Carbon | ||||
| Steels - Mild | ||||
| Steels - Stainless | ||||
| Non-ferrous alloys - Aluminium | ||||
| Non-ferrous alloys - Copper | ||||
| Non-ferrous alloys - Lead | ||||
| Non-ferrous alloys - Magnesium | ||||
| Non-ferrous alloys - Nickel | ||||
| Non-ferrous alloys - Tin | ||||
| Non-ferrous alloys - Zinc | ||||
| Cold heading for low to medium carbon steels - axial tolerances | 1-300mm | 0.005-0.5mm | ||
| Cold heading for low to medium carbon steels - radial tolerances | 1-30mm | 0.005-0.2mm | ||
| Impact extrusion - axial tolerances | 5-150mm | 0.05-2mm | Steels - Alloy | |
| Steels - High Carbon | ||||
| Steels - Medium Carbon | ||||
| Steels - Mild | ||||
| Steels - Stainless | ||||
| Non-ferrous alloys - Aluminium | ||||
| Non-ferrous alloys - Copper | ||||
| Non-ferrous alloys - Lead | ||||
| Non-ferrous alloys - Magnesium | ||||
| Non-ferrous alloys - Nickel | ||||
| Non-ferrous alloys - Tin | ||||
| Non-ferrous alloys - Zinc | ||||
| Impact extrusion - radial tolerances | 5-150mm | 0.01-2mm | Steels - Alloy | |
| Steels - High Carbon | ||||
| Steels - Medium Carbon | ||||
| Steels - Mild | ||||
| Steels - Stainless | ||||
| Non-ferrous alloys - Aluminium | ||||
| Non-ferrous alloys - Copper | ||||
| Non-ferrous alloys - Lead | ||||
| Non-ferrous alloys - Magnesium | ||||
| Non-ferrous alloys - Nickel | ||||
| Non-ferrous alloys - Tin | ||||
| Non-ferrous alloys - Zinc | ||||
| Swaging | 10-150mm | 0.01-1mm | Steels - Alloy | |
| Steels - High Carbon | ||||
| Steels - Medium Carbon | ||||
| Steels - Mild | ||||
| Steels - Stainless | ||||
| Non-ferrous alloys - Aluminium | ||||
| Non-ferrous alloys - Copper | ||||
| Non-ferrous alloys - Lead | ||||
| Non-ferrous alloys - Magnesium | ||||
| Non-ferrous alloys - Nickel | ||||
| Non-ferrous alloys - Tin | ||||
| Non-ferrous alloys - Zinc | ||||
| Elastomer and composite moulding | Compression moulding for composite materials | 10-3000mm | 0.05-10mm | |
| Hand-spray lay-up for composite materials | 10-5000mm | 0.1-50mm | ||
| Injection moulding for elastomers | 1-150mm | 0.01-2mm | ||
| Extrusion | Cold extrusion | 1-150mm | 0.005-0.2mm | Steels - Alloy |
| Steels - High Carbon | ||||
| Steels - Medium Carbon | ||||
| Steels - Mild | ||||
| Steels - Stainless | ||||
| Non-ferrous alloys - Aluminium | ||||
| Non-ferrous alloys - Copper | ||||
| Non-ferrous alloys - Lead | ||||
| Non-ferrous alloys - Magnesium | ||||
| Non-ferrous alloys - Nickel | ||||
| Non-ferrous alloys - Tin | ||||
| Non-ferrous alloys - Zinc | ||||
| Extrusion for elastomers | 1-100mm | 0.1-10mm | ||
| Extrusion for thermoplastics | 1-500mm | 0.01-20mm | ||
| Hot extrusion for aluminium and magnesium alloys | 1-300mm | 0.05-5mm | ||
| Hot forging | Closed die forging upto 1kg - low to medium carbon | 5-300mm | 0.1-3mm | |
| Closed die forging 1kg to 3.2kg - low to medium carbon | 10-500mm | 0.2-5mm | ||
| Closed die forging 3.2kg to 10kg - low to medium carbon | 10-1000mm | 0.5-10mm | ||
| Closed die forging 10kg to 50kg - low to medium carbon | 10-1500mm | 0.5-10mm | ||
| Closed die forging upto 1kg - low alloy steel | 5-300mm | 0.1-3mm | ||
| Closed die forging 1kg to 3.2kg - low alloy steel | 10-500mm | 0.2-5mm | ||
| Closed die forging 3.2kg to 10kg - low alloy steel | 10-1000mm | 0.5-10mm | ||
| Closed die forging 10kg to 50kg - low alloy steel | 10-1500mm | 0.5-10mm | ||
| Precision closed die forging and stamping for copper alloys | 1-300mm | 0.01-1mm | ||
| Machining | Broaching | 1-150mm | 0.001-0.05mm | Steels - Alloy |
| Steels - Cast | ||||
| Steels - Free cutting | ||||
| Steels - High Carbon | ||||
| Steels - Medium Carbon | ||||
| Steels - Mild | ||||
| Steels - Stainless | ||||
| Steels - Tool | ||||
| Non-ferrous alloys - Aluminium | ||||
| Non-ferrous alloys - Copper | ||||
| Non-ferrous alloys - Lead | ||||
| Non-ferrous alloys - Magnesium | ||||
| Non-ferrous alloys - Nickel | ||||
| Non-ferrous alloys - Tin | ||||
| Non-ferrous alloys - Titanium | ||||
| Non-ferrous alloys - Zinc | ||||
| Irons - Grey | ||||
| Cylindrical grinding | 1-1000mm | 0.0005-0.1mm | Steels - Alloy | |
| Steels - Cast | ||||
| Steels - Free cutting | ||||
| Steels - High Carbon | ||||
| Steels - Medium Carbon | ||||
| Steels - Mild | ||||
| Steels - Stainless | ||||
| Steels - Tool | ||||
| Non-ferrous alloys - Nickel | ||||
| Non-ferrous alloys - Titanium | ||||
| Irons - Grey | ||||
| Irons - Malleable | ||||
| Irons - Nodular | ||||
| Irons - Pearlite | ||||
| Drilling | 1-100mm | 0.005-1mm | Steels - Alloy | |
| Steels - Cast | ||||
| Steels - Free cutting | ||||
| Steels - High Carbon | ||||
| Steels - Medium Carbon | ||||
| Steels - Mild | ||||
| Steels - Stainless | ||||
| Steels - Tool | ||||
| Non-ferrous alloys - Aluminium | ||||
| Non-ferrous alloys - Copper | ||||
| Non-ferrous alloys - Lead | ||||
| Non-ferrous alloys - Magnesium | ||||
| Non-ferrous alloys - Nickel | ||||
| Non-ferrous alloys - Tin | ||||
| Non-ferrous alloys - Titanium | ||||
| Non-ferrous alloys - Zinc | ||||
| Irons - Grey | ||||
| Honing | 1-500mm | 0.0005-0.05mm | Steels - Alloy | |
| Steels - Cast | ||||
| Steels - Free cutting | ||||
| Steels - High Carbon | ||||
| Steels - Medium Carbon | ||||
| Steels - Mild | ||||
| Steels - Stainless | ||||
| Steels - Tool | ||||
| Non-ferrous alloys - Nickel | ||||
| Non-ferrous alloys - Titanium | ||||
| Irons - Grey | ||||
| Irons - Malleable | ||||
| Irons - Nodular | ||||
| Irons - Pearlite | ||||
| Lapping | 1-500mm | 0.0005-0.05mm | Steels - Alloy | |
| Steels - Cast | ||||
| Steels - Free cutting | ||||
| Steels - High Carbon | ||||
| Steels - Medium Carbon | ||||
| Steels - Mild | ||||
| Steels - Stainless | ||||
| Steels - Tool | ||||
| Non-ferrous alloys - Nickel | ||||
| Non-ferrous alloys - Titanium | ||||
| Irons - Grey | ||||
| Irons - Malleable | ||||
| Irons - Nodular | ||||
| Irons - Pearlite | ||||
| Milling | 1-1000mm | 0.005-1mm | Steels - Alloy | |
| Steels - Cast | ||||
| Steels - Free cutting | ||||
| Steels - High Carbon | ||||
| Steels - Medium Carbon | ||||
| Steels - Mild | ||||
| Steels - Stainless | ||||
| Steels - Tool | ||||
| Non-ferrous alloys - Aluminium | ||||
| Non-ferrous alloys - Copper | ||||
| Non-ferrous alloys - Lead | ||||
| Non-ferrous alloys - Magnesium | ||||
| Non-ferrous alloys - Nickel | ||||
| Non-ferrous alloys - Tin | ||||
| Non-ferrous alloys - Titanium | ||||
| Non-ferrous alloys - Zinc | ||||
| Irons - Grey | ||||
| Planing and shaping | 10-2000mm | 0.01-1mm | Steels - Alloy | |
| Steels - Cast | ||||
| Steels - Free cutting | ||||
| Steels - High Carbon | ||||
| Steels - Medium Carbon | ||||
| Steels - Mild | ||||
| Steels - Stainless | ||||
| Steels - Tool | ||||
| Non-ferrous alloys - Aluminium | ||||
| Non-ferrous alloys - Copper | ||||
| Non-ferrous alloys - Lead | ||||
| Non-ferrous alloys - Magnesium | ||||
| Non-ferrous alloys - Nickel | ||||
| Non-ferrous alloys - Tin | ||||
| Non-ferrous alloys - Titanium | ||||
| Non-ferrous alloys - Zinc | ||||
| Irons - Grey | ||||
| Reaming | 1-100mm | 0.001-0.1mm | Steels - Alloy | |
| Steels - Cast | ||||
| Steels - Free cutting | ||||
| Steels - High Carbon | ||||
| Steels - Medium Carbon | ||||
| Steels - Mild | ||||
| Steels - Stainless | ||||
| Steels - Tool | ||||
| Non-ferrous alloys - Aluminium | ||||
| Non-ferrous alloys - Copper | ||||
| Non-ferrous alloys - Lead | ||||
| Non-ferrous alloys - Magnesium | ||||
| Non-ferrous alloys - Nickel | ||||
| Non-ferrous alloys - Tin | ||||
| Non-ferrous alloys - Titanium | ||||
| Non-ferrous alloys - Zinc | ||||
| Irons - Grey | ||||
| Surface grinding | 1-1000mm | 0.0005-0.1mm | Steels - Alloy | |
| Steels - Cast | ||||
| Steels - Free cutting | ||||
| Steels - High Carbon | ||||
| Steels - Medium Carbon | ||||
| Steels - Mild | ||||
| Steels - Stainless | ||||
| Steels - Tool | ||||
| Non-ferrous alloys - Nickel | ||||
| Non-ferrous alloys - Titanium | ||||
| Irons - Grey | ||||
| Irons - Malleable | ||||
| Irons - Nodular | ||||
| Irons - Pearlite | ||||
| Turning and boring | 5-5000mm | 0.001-0.5mm | Steels - Alloy | |
| Steels - Cast | ||||
| Steels - Free cutting | ||||
| Steels - High Carbon | ||||
| Steels - Medium Carbon | ||||
| Steels - Mild | ||||
| Steels - Stainless | ||||
| Steels - Tool | ||||
| Non-ferrous alloys - Aluminium | ||||
| Non-ferrous alloys - Copper | ||||
| Non-ferrous alloys - Lead | ||||
| Non-ferrous alloys - Magnesium | ||||
| Non-ferrous alloys - Nickel | ||||
| Non-ferrous alloys - Tin | ||||
| Non-ferrous alloys - Titanium | ||||
| Non-ferrous alloys - Zinc | ||||
| Irons - Grey | ||||
| Ultra precision turning and boring | 1-1000mm | 0.0005-0.1mm | Steels - Alloy | |
| Steels - Cast | ||||
| Steels - Free cutting | ||||
| Steels - High Carbon | ||||
| Steels - Medium Carbon | ||||
| Steels - Mild | ||||
| Steels - Stainless | ||||
| Steels - Tool | ||||
| Non-ferrous alloys - Aluminium | ||||
| Non-ferrous alloys - Copper | ||||
| Non-ferrous alloys - Lead | ||||
| Non-ferrous alloys - Magnesium | ||||
| Non-ferrous alloys - Nickel | ||||
| Non-ferrous alloys - Tin | ||||
| Non-ferrous alloys - Titanium | ||||
| Non-ferrous alloys - Zinc | ||||
| Irons - Grey | ||||
| Non-traditional machining | Chemical milling for aluminium alloys | 1-15mm | 0.005-0.2mm | |
| Chemical milling for carbon steels | 1-15mm | 0.01-0.5mm | ||
| Chemical milling for titanium | 1-15mm | 0.01-0.5mm | ||
| Electrical discharge machining | 1-100mm | 0.001-0.2mm | ||
| Electrochemical machining | 1-100mm | 0.001-0.5mm | ||
| Electron beam machining | 1-100mm | 0.001-0.5mm | ||
| Laser beam machining | 1-100mm | 0.001-0.5mm | ||
| Photochemical blanking for carbon steels | 0.01-1mm | 0.005-0.5mm | ||
| Photochemical blanking for copper alloys | 0.01-1mm | 0.001-0.2mm | ||
| Ultrasonic machining | 1-100mm | 0.001-0.2mm | ||
| Plastic moulding | Blow moulding - thermoplastics | 10-500mm | 0.1-5mm | |
| Injection or compression moulding ABS, EPOXY, PBTP (filled), PC, PESU | 1-1000mm | 0.01-10mm | ||
| Injection or compression moulding PETP (filled), PF, PMMA, POM (filled), PPS | 1-1000mm | 0.01-10mm | ||
| Injection or compression moulding PS, PSU, PVC-U, SAN, UP | 1-1000mm | 0.01-10mm | ||
| Injection or compression moulding CA, CP, PA, PBTP (unfilled), PP (filled) | 1-1000mm | 0.01-10mm | ||
| Injection or compression moulding PCTFE, PE, PP (unfilled) | 1-1000mm | 0.01-10mm | ||
| Injection moulding for precision engineering components (All thermoplastics) | 1-500mm | 0.01-1mm | ||
| Rotational moulding for thermoplastics | 100-4000mm | 0.2-20mm | ||
| Injection Moulding Low Shrinkage (& DIN/ISO Cross Ref) | 1-1000mm | 0.01-10mm | ||
| Injection Moulding Medium Shrinkage (& DIN/ISO Cross Ref) | 1-1000mm | 0.01-10mm | ||
| Injection Moulding High Shrinkage (& DIN/ISO Cross Ref) | 1-1000mm | 0.01-10mm | ||
| Powder metallurgy | Powder metal sintering for axial tolerances | 1-100mm | 0.01-1mm | Steels - Alloy |
| Steels - High Carbon | ||||
| Steels - Medium Carbon | ||||
| Steels - Mild | ||||
| Steels - Stainless | ||||
| Steels - Tool | ||||
| Non-ferrous alloys - Aluminium | ||||
| Non-ferrous alloys - Copper | ||||
| Non-ferrous alloys - Nickel | ||||
| Non-ferrous alloys - Titanium | ||||
| Irons - Malleable | ||||
| Powder metal sintering for radial tolerances | 1-100mm | 0.001-0.5mm | Steels - Alloy | |
| Steels - High Carbon | ||||
| Steels - Medium Carbon | ||||
| Steels - Mild | ||||
| Steels - Stainless | ||||
| Steels - Tool | ||||
| Non-ferrous alloys - Aluminium | ||||
| Non-ferrous alloys - Copper | ||||
| Non-ferrous alloys - Nickel | ||||
| Non-ferrous alloys - Titanium | ||||
| Irons - Malleable | ||||
| Powder metal sizing for radial tolerances | 1-100mm | 0.001-1mm | Steels - Alloy | |
| Steels - High Carbon | ||||
| Steels - Medium Carbon | ||||
| Steels - Mild | ||||
| Steels - Stainless | ||||
| Steels - Tool | ||||
| Non-ferrous alloys - Aluminium | ||||
| Non-ferrous alloys - Copper | ||||
| Non-ferrous alloys - Nickel | ||||
| Non-ferrous alloys - Titanium | ||||
| Irons - Malleable | ||||
| Sheet metalworking | Deep drawing and ironing | 1-500mm | 0.001-1mm | Steels - Alloy |
| Steels - High Carbon | ||||
| Steels - Medium Carbon | ||||
| Steels - Mild | ||||
| Steels - Stainless | ||||
| Non-ferrous alloys - Aluminium | ||||
| Non-ferrous alloys - Copper | ||||
| Non-ferrous alloys - Lead | ||||
| Non-ferrous alloys - Magnesium | ||||
| Non-ferrous alloys - Nickel | ||||
| Non-ferrous alloys - Tin | ||||
| Non-ferrous alloys - Titanium | ||||
| Non-ferrous alloys - Zinc | ||||
| Fine blanking | 1-500mm | 0.001-0.5mm | Steels - Alloy | |
| Steels - High Carbon | ||||
| Steels - Medium Carbon | ||||
| Steels - Mild | ||||
| Steels - Stainless | ||||
| Non-ferrous alloys - Aluminium | ||||
| Non-ferrous alloys - Copper | ||||
| Non-ferrous alloys - Lead | ||||
| Non-ferrous alloys - Magnesium | ||||
| Non-ferrous alloys - Nickel | ||||
| Non-ferrous alloys - Tin | ||||
| Non-ferrous alloys - Titanium | ||||
| Non-ferrous alloys - Zinc | ||||
| Sheet metal bending | 1-1000mm | 0.05-5mm | Steels - Alloy | |
| Steels - High Carbon | ||||
| Steels - Medium Carbon | ||||
| Steels - Mild | ||||
| Steels - Stainless | ||||
| Non-ferrous alloys - Aluminium | ||||
| Non-ferrous alloys - Copper | ||||
| Non-ferrous alloys - Lead | ||||
| Non-ferrous alloys - Magnesium | ||||
| Non-ferrous alloys - Nickel | ||||
| Non-ferrous alloys - Tin | ||||
| Non-ferrous alloys - Titanium | ||||
| Non-ferrous alloys - Zinc | ||||
| Sheet metal cutting | 1-3000mm | 0.01-2mm | Steels - Alloy | |
| Steels - High Carbon | ||||
| Steels - Medium Carbon | ||||
| Steels - Mild | ||||
| Steels - Stainless | ||||
| Non-ferrous alloys - Aluminium | ||||
| Non-ferrous alloys - Copper | ||||
| Non-ferrous alloys - Lead | ||||
| Non-ferrous alloys - Magnesium | ||||
| Non-ferrous alloys - Nickel | ||||
| Non-ferrous alloys - Tin | ||||
| Non-ferrous alloys - Titanium | ||||
| Non-ferrous alloys - Zinc | ||||
| Sheet metal punching | 1-300mm | 0.01-0.5mm | Steels - Alloy | |
| Steels - High Carbon | ||||
| Steels - Medium Carbon | ||||
| Steels - Mild | ||||
| Steels - Stainless | ||||
| Non-ferrous alloys - Aluminium | ||||
| Non-ferrous alloys - Copper | ||||
| Non-ferrous alloys - Lead | ||||
| Non-ferrous alloys - Magnesium | ||||
| Non-ferrous alloys - Nickel | ||||
| Non-ferrous alloys - Tin | ||||
| Non-ferrous alloys - Titanium | ||||
| Non-ferrous alloys - Zinc | ||||
| Sheet metal roll forming | 10-1500mm | 0.01-2mm | Steels - Alloy | |
| Steels - High Carbon | ||||
| Steels - Medium Carbon | ||||
| Steels - Mild | ||||
| Steels - Stainless | ||||
| Non-ferrous alloys - Aluminium | ||||
| Non-ferrous alloys - Copper | ||||
| Non-ferrous alloys - Lead | ||||
| Non-ferrous alloys - Magnesium | ||||
| Non-ferrous alloys - Nickel | ||||
| Non-ferrous alloys - Tin | ||||
| Non-ferrous alloys - Titanium | ||||
| Non-ferrous alloys - Zinc | ||||
| Sheet metal spinning | 50-5000mm | 0.01-5mm | Steels - Alloy | |
| Steels - High Carbon | ||||
| Steels - Medium Carbon | ||||
| Steels - Mild | ||||
| Steels - Stainless | ||||
| Non-ferrous alloys - Aluminium | ||||
| Non-ferrous alloys - Copper | ||||
| Non-ferrous alloys - Lead | ||||
| Non-ferrous alloys - Magnesium | ||||
| Non-ferrous alloys - Nickel | ||||
| Non-ferrous alloys - Tin | ||||
| Non-ferrous alloys - Titanium | ||||
| Non-ferrous alloys - Zinc |