This page includes prototye fabricators, and my expected tolerances from different manufacturing processes.
Fabricators
Processes
| Method |
Common Components And Uses |
Profile Tolerance (my values in 2024) |
| 3D printing, DMLS |
- Fluid paths and manifolds, where conventional manufacturing methods cannont produce the geometry.
|
±0.15 mm |
| 3D printing, FDM |
- Prototyping parts. It is unusual to use FDM for production parts.
|
±0.45 mm |
| 3D printing, SLS |
- Low volume plastic parts, where where tooling costs for vaccuum forming or injection moulding are acceptable.
- Complex geometry, that does not allow moulding or machining.
- Air ducts.
- Camera mounting brackets (which often are mounted on complex angles).
|
±0.25 mm |
| Forming, Sheet Metal |
- Chassis.
- Body panels.
- Brackets and structures for mounting components.
|
±0.75 mm |
| Injection Moulding |
- Aesthetic panels and covers.
|
±0.15 mm |
| Laser Cutting |
- Sheet metal panels, covers, and chassis.
- Plastic insulating covers, and terminal blocks.
|
±0.25 mm |
| Machining (Milling and Turning) |
- Drivetrain rotating components.
- O-ring grooves.
|
±0.15 mm |
| Moulding, Carbon Fibre and Fibreglass |
- Aesthetic panels and covers.
- Chassis, if sheet metal is not a viable option.
|
Depends on process and material. Post moulding machining tolerances can be ±0.15 mm. |
| Waterjet Cutting |
- Glass lenses.
- Foam and rubber gaskets.
- Sheet metal.
|
±0.15 mm |
| Welding |
- Steel and aluminum welding, with processes including MIG, TIG, and laser.
- Different material thicknesses and profiles.
|
Depends on the process. High tolerances of ±0.45 mm can be achieved with fixtures, and considering thermal expansion of materials. |