FAQ's

Frequently Asked Questions

Got Questions? We’ve Got Answers!

Getting Started Getting Started

  • Innowerx Manufacturing Services is a private limited company established on 14th December 2021 by Founder and Managing Director, Mr. Vivek Kudva. The company aims to provide end to end manufacturing services to technology and engineering companies located overseas.
  • Manufacturing industries are in an eternal struggle of delivering and maintaining value of their products in the market. One important aspect in improving the viability of the product is by cutting down the manufacturing cost while maintaining good quality. We help our clients achieve their sustainability goals by taking onus of the manufacturing operations right from prototyping to mass production.
  • Our regular office working hours (IST) are :
    Day Working Hours
    Monday 09:00 – 21:00
    Tuesday 09:00 – 21:00
    Wednesday 09:00 – 21:00
    Thursday 09:00 – 21:00
    Friday 09:00 – 21:00
    Saturday 09:00 – 18:00
  • Any query / enquiry / complaint received during non-working hours is recorded in our system and addressed on an immediate working day.
  • Innowerx keeps your information secure and private. If needed, we can execute an NDA for clients who require this documentation.
  • We can share our standard NDA or you can also send us a copy of your company's NDA.
  • You may mail your NDA to info@innowerx.com or directly to your BDR.
  • You can reach out to us through this platform by three different ways :
    • WhatsApp – This icon is available in the social media tab in the footer section of the webpage. A click on this icon will directly connect you with our Business Development Representative (BDR) who shall address all your queries.
    • Chat bot – This is visible on the bottom right corner of your screen. The information collected through this application will be recorded and received by our BDR which will enable us to get in touch with you. Our BDR’s are available for live chat during the office working hours and shall respond to you immediately. In case of any missed-out messages, our BDR will contact you through call, email, and any other communication media to get a detailed understanding of your requirement.
    • Enquiry form – This is available on the Contact Us page. The information filled in this form will be received by us via email. You may attach any one file relevant to your enquiry. Our BDR will contact you through call, email, and any other communication media.
  • You can reach out to us through this platform by three different ways :
    • Social media – We have our presence on various social media platforms indicated in the footer section of this webpage in the form of icons. A click on these icons will take you to the respective platform through which you may interact with us via the communication means provided on the platform. The WhatsApp icon will directly connect you with our Business Development Representative (BDR).
    • Chat bot – This is visible on the bottom right corner of your screen. The information collected through this application will be received by our BDR which will enable us to get in touch with you. Our BDR’s are available for live chat during the office working hours and shall respond to you immediately. In case of any missed-out messages, the same is recorded in this application and our BDR will contact you through call, email, and any other communication media.
    • Enquiry form – This is available on the Contact Us page. The information filled in this form will be received by us via email. You may attach any one file relevant to your enquiry. Our BDR will contact you through call, email, and any other communication media to get a detailed understanding of your requirement.
  • Enquiries shall be floated through this platform by three different ways as explained in the previous FAQ.
  • The BDR will acknowledge the receipt of enquiry within 1 working day.
  • The preliminary details shared by you will be reviewed and additional information will be requested as the need may arise. Few basic documents needed for prompt addressal of enquiry include part drawing, relevant product and process specification, BOM, project scope etc.
  • After a detailed understanding of the project, a techno-commercial quote will be shared with you.
  • You can raise a query through this platform by three different ways as explained in the previous FAQ.
  • If you have any complaint with regards to the content posted on this platform, you may write to us at info@innowerx.com.
  • If you have any complaint with regards to the product or service, you may directly contact your BDR.
  • In case of any query, enquiry or complaint our BDR shall respond to you within 1 working day.
  • We provide a wide range of manufacturing services as listed on the Home page of this platform. Specific details pertaining to each service can be viewed by clicking on the relevant icon. Few services offered by us on a broader level are :
    • Casting
    • Forging
    • Precision Machining
    • Sheet Metal
    • Plastic Injection Molding
    • Heat Treatment
    • Surface Treatment
    • Welding
    • 3D Printing
    • Testing and Assembly
  • However, our services are not limited to those specified on this platform. Our portfolio is dynamic and constantly upgraded as we solve the challenges faced by our clients. For more details you may reach out to us through our Contact Us page.
  • Our Quality Management System is in-line with international quality standards such as IATF 16949 and AS 9100.
  • We follow specific quality tools on project basis to achieve the best output. Some of the tools are APQP, Six Sigma, 6S, FMEA, KAIZEN etc. Refer the About section for more details.
  • Parts are inspected at every stage to ensure 100% compliance to customer requirements. Final inspection details are shared with the client for approval prior to the shipment.
  • The timeliness of delivery is a result of efficient allocation of resources and effective planning techniques. To know more go to our About section.
  • Innowerx follows a lean management system and therefore limits itself from making any unnecessary capital investments. This not only enables it to be more competitive, but also provide unrestricted and tailored manufacturing solutions at one place, by capitalizing on its vast and competent supplier network. Our team of professionals are involved throughout the product development process with the support of our infrastructure developed to assist in the last mile activities such as :
    • Inspection and Testing
    • Assembly
    • Packaging and Shipping
  • Some of the pictures posted on this platform does not relate to the actual process or product manufactured by Innowerx and only demonstrates the nature of product, process, and service that it can offer. This is in honor of the agreement we have with our clients which might restrict us from sharing any client specific information on the public domain. To get an actual glimpse of our portfolio, you may reach out to us directly through our Contact Us page.
  • The images used on this platform do not infringe any Copyright or IP protocols and used by Innowerx in agreement with the source of the image or those available in the public platform.
  • Our supplier network is the strongest pillar of our value chain. Partner with us today on this journey of collective growth and drive the change. For more details visit For Supplier page.
  • Our workforce is the most valuable asset of our business. To be inducted in the Innowerx family, you shall share your work profile on hr@innowerx.com. You may also do so by referring to the vacancies posted on Career page and submitting the available form with correct details.
  • Our HR team shall review your profile and respond to you within 2 working days. Recruitment is carried out as per our HR policy.

Casting Casting

  • Yes, sand casting being a very raw and inexpensive process is commonly used for prototyping. The cost of making die and mold is much cheaper compared to other forms of casting process.
  • As sand castings are more susceptible to inherent defects and lower throughput, they can’t be directly considered as a reflection of final product in case of mass production.
  • Due to complexities in the investment casting process, numerous defects can be observed such as :
    • Inclusions – Presence of foreign particles
    • Hot tear – When there is restriction to shrinkage of molten metal by ceramic shell mold during cooling
    • Misrun – When molten metal is unable to fill mold cavity completely
    • Cold shut – When two metal streams do not fuse together properly in the mold cavity
    • Runout – When molten metal leaks out of mold while pouring
    • Shrinkage – It occurs when there is a change is casting section
    • Wax damage – When the wax pattern has been mishandled
    • Bulge – Wax patterns too close resulting in ceramic shell bridging
  • Pros
    • High dimensional accuracy
    • Require minimum machining
    • Lower restriction on part size
    • Make parts with lower wall thickness
    • Automated process with shorter lead times
  • Cons
    • High tooling cost
    • Can’t be used for ferrous alloys
    • Suitable only for mass production
  • Gas porosities – Due to gas entrapment
  • Drags – Damage on the surface of die cavity and insufficient hardness
  • Cracks – High Fe element. Low die temperature. Non uniform wall thickness
  • Deformation – Poor casting structural design
  • Sinks – Injection pressure too low. Uneven wall thickness of the casting
  • Short filling – Poor fluidity of molten metal. Low injection pressure
  • Flashes – Injection speed too high. Clamping force of die is insufficient
  • We have developed and keep upgrading our capabilities by adding professional and experienced vetted suppliers to our vendor network. Please refer to Capability section of this page for more details.

Forging Forging

  • It is a manufacturing process which involves shaping of metal through hammering, pressing, or rolling. It can be broadly classified as Open die and Closed die forging.
  • The various types of forging process that we can undertake for your parts are ring rolling, radial forging, orbital forging, upset forging, extrusion forging etc. For more details, please refer the Overview section of this page.
  • Forged parts have higher strength and toughness and is less susceptible to cracking and shearing under compressive load. Forgings have minimal defects which can be refined by pre-working.
  • They have a better response to heat treatment and have a lower cost over component life.
  • Castings are preferred to make more complex shaped parts with varying thickness.
  • Forged parts are commonly found at point of stress and shock. Automotives such as cars and trucks consist of more than 250 forged parts most of which are produced from carbon or alloy steel. Few of the parts include connecting rods, crankshafts, gear and pinion, universal joints, rocker arms etc.
  • Other industries which require forgings include Aerospace and Defence, Oil & Gas, Steel, Valves etc.
  • There can be multiple imperfections in a forging which if present prominently can be termed as a defect. Few of them are :
    • Unfilled section – Some part of the forging section remains unfilled.
    • Cold shut – It includes small cracks at the corners.
    • Scale pits – Due to improper cleaning of forged surface.
    • Die shift – Due to misalignment of upper and lower die.
    • Residual stress and Flakes – Due to improper cooling of forge product.
    • Surface cracking – Due to excessive working on surface at low temperature.
  • Chemical analysis – To ascertain the chemistry of the material usually done by spectrometry.
  • Mechanical testing – To verify the mechanical properties such as strength, hardness, and ductility. Various tests performed include hardness test, tensile test, bend test, fracture toughness, fatigue test etc.
  • NDT – To verify any surface or internal defects in forging. We perform Ultrasonic, Radiography, Magnetic particle, and Liquid penetrant test.
  • Metallurgical test – To evaluate the physical characteristics of the forged material and check for any defects. This includes microstructure, macrostructure, and grain size.
  • We have developed and keep upgrading our capabilities by adding professional and experienced vetted suppliers to our vendor network. Please refer to Capability section of this page for more details.

Precision Machining Precision Machining

  • Traditional machining involves removal or forming of metal from a stock manually, by a skilled machinist. The stock is mounted on the machine with the help of chuck, vice, fixtures, steady rest and a variety of cutting tools made of hardened steel, carbide and other grades are used to machine the metal.
  • CNC machine performs the same function but the only difference being it is computer numeric control rather than manual control by a machinist. The programmer writes the code as to control the movement of the tool mounted on the turret which in turn performs the machining operation. The different operating parameters (speed, feed, rpm, depth of cut etc.) can be modified based on the material and dimensional requirements.
  • CNC machined parts are more precise, accurate and have better repeatability. They are usually preferred for high volume production as it gives a better throughput. Parts which are to be made in close tolerance are preferably manufactured on CNC machine.
  • Due to complexities in the investment casting process, numerous defects can be observed such as :
    • We can perform almost all kinds of machining operations such as turning, milling, drilling, broaching, ECM/EDM, CNC turning, vertical turning, VMC machining (with and without 4th axis), 5 axis VMC machining, boring, deep hole drilling, polishing, grinding (flat and cylindrical), honing, burnishing, superfinishing and many more.
  • We have developed and keep upgrading our capabilities by adding professional and experienced vetted suppliers to our vendor network. Please refer to Capability section of this page for more details.
  • The machining process is analyzed based on Process Capability Analysis. CTQ’s are defined for the part as per the requirement of the drawing. Batches are prepared based on the quantity of production order and the actual CTQ dimensions are mapped on the run chart after inspection. Suitable action is taken based on the trend analysis to ensure the parts are produced within the defined control limits.
  • Control Charts is the most simple and effective way of producing conforming parts with the highest degree of consistency. This process is followed by us as part of PPAP (Production Part Approval Process) based on project requirement or as requested by the Client.
  • The final drawing and specifications provided by the Client during order finalization is taken as a reference for manufacturing the parts. The CTQ dimensions are key characteristics are defined.
  • The parts are inspected at every stage and after it is finish machined using calibrated measuring instruments such as micrometers, verniers, gauges etc.
  • Critical parts are also inspected using sophisticated measuring equipment’s such as CMM (Coordinate Measuring Machine), profile meter, microscope, and NDT instruments.
  • We can manufacture parts as small as 1” in diameter and length and ranging up to 60” in diameter and 300” in length.
  • We can make a variety of parts such as sleeves, mandrels, piston rods, plungers, domes, screws and barrels, flanges, spindles, diffusers, scrolls, shafts etc.
  • There is no restriction as to the type of part we manufacture as long as we are able to meet the design requirements through our diversified machining capabilities.
  • CNC machining allows us to achieve tight tolerance of up to ±0.05mm. The accuracy achieved also depends on the machine selection, fixturing, process consumables and operating parameters.
  • Higher accuracy of up to ±0.005mm can be achieved by grinding, polishing, honing etc.
  • We can make a variety of parts for the Automotive and Aerospace industry which are critical and have stringent quality norms.
  • Other sectors where we provide machined parts include Oil & Gas, Steel, Power Generation, Plastic Extrusion, Marine, Pumps, Valves etc.

Sheet Metal Sheet Metal

  • Sheet metal is made by passing a hot metal slab through a series of rollers that make them thinner and longer. To make it even thinner and achieve the desired sheet thickness it is passed through finishing rolling stands and then cooled and rolled into coils.
  • In cold forming the metal is subjected to forces at room temperature whereas in hot forming the metal is heated to a high temperature making it easier to form it into complex shapes.
  • Cold forming requires higher forming forces but also delivers high precision, high quality surface finishes and high-speed production.
  • Before designing a part, the most basic input needed is the material and size selection.
  • Few factors that the designer needs to consider while modelling a sheet metal component include wall thickness, bend radii, orientation of holes and slots, K-factor, bend allowance, bend reliefs etc.
  • Our range of services in sheet metal part manufacturing can be broadly classified as fabrication, stamping, deep drawing and spinning.
  • Few commonly carried processes in stamping include blanking, piercing, notching, trimming, parting off, perforating, shaving, lancing, louvering, broaching etc.
  • We can manufacture the press tools suitable to produce the final sheet metal part. This includes both prototype and production tooling.
  • Depending on the part design we can manufacture different types of tools such as progressive tool, compound tool, combination tool etc.
  • The part design shared by the customer is reviewed and notable suggestions are given to improve manufacturing feasibility wherever possible. The parts are simulated for design and function and taken up for manufacturing feasibility review.
  • Tentative process flow is created and tooling’s are designed accordingly to simulate the manufacturing process.
  • Any recommendation for design change is communicated and approved from the customer and the part design is finalized after its passes the simulation.
  • The proto tool is manufactured, and a pilot lot is stamped to check conformity to design requirement.
  • On approval of proto parts, the production tooling is manufactured and taken on the allocated press for manufacturing of production lot.
  • We have developed and keep upgrading our capabilities by adding professional and experienced vetted suppliers to our vendor network. Please refer to Capability section of this page for more details.

Plastic Injection Molding Plastic Injection Molding

  • Plastic injection molding is the process of melting plastic pellets (thermosetting/thermoplastic polymers) that once malleable enough, are injected at pressure into a mold cavity, which fills and solidifies to produce the final product. The six main stages of production include :
    • Closing of mold
    • Injection
    • Cooling
    • Plasticizing the resin
    • Ejection
    • Removing the runner
  • Pros
    • Can be used to produce intricate parts with high precision
    • High repeatability
    • Low cost per part
    • Very fast process ideal for mass production
    • Wide range of material choice
    • Special surface finish with possibility of engraving and printing
    • Minimal plastic waste
  • Cons
    • High initial cost
    • Initial lead time
    • Large part size limitations
    • Designing must be perfect considering all factors
  • Flow lines – Due to varying speed at which the molten plastic flows as it changes direction through the contours and bends.
  • Sink marks – When the cooling time or cooling mechanism is insufficient.
  • Vacuum voids - Uneven solidification between the surface and the inner sections of the prototype.
  • Surface delamination - Foreign materials that find their way into the molten plastic separate from the finished product because the contaminant and the plastic cannot bond.
  • Weld lines - Inadequate bonding of two or more flow fronts when there is partial solidification of the molten plastic.
  • Warping – Non-uniform cooling of the mold material.
  • Burn marks - Caused either by the degradation of the plastic material due to excessive heating or by injection speeds that are too fast.
  • Jetting - Melt temperature is too low, and the viscosity of the molten plastic becomes too high, thereby increasing the resistance of its flow through the mold.
  • Flash – It can occur when the mold is not clamped together with enough force (a force strong enough to withstand the opposing forces generated by the molten plastic flowing through the mold), which allows the plastic to seep through.
  • • We have developed and keep upgrading our capabilities by adding professional and experienced vetted suppliers to our vendor network. Please refer to Capability section of this page for more details.

Heat Treatment Heat Treatment

  • It is a thermal process in which the metal is heated above its re-crystallization temperature without letting it reach its molten stage and then cooling the metal in a controlled environment to alter its physical and sometimes chemical properties.
  • Heat treatment is usually done to make a metal stronger, more malleable, resistant to abrasion or ductile.
  • The three main stages in heat treatment are Heating, Soaking and Cooling.
  • The purpose of heat treatment is to improve wear resistance, fatigue strength, machinability, cold press property, other physical properties such as magnetic property etc.
  • The Fe - C diagram (also called the iron - carbon phase or equilibrium diagram) is a graphic representation of the respective microstructure states of the alloy iron - carbon (Fe-C) depending on temperature and carbon content. It is a universal diagram as it covers all Fe-C alloys.
  • The various phases which exist in Fe – C diagram include ferrite, cementite, austenite, pearlite, ferrite + austenite and austenite + cementite.
  • The Fe – C diagram considers very slow cooling or equilibrium cooling.
  • If solubility of carbon is more than 2% in iron, it is theoretically called as cast iron. Balance carbon is present in free form in the form of granules or flakes.
  • Ferrite – Interstitial solid solution of carbon in iron of body centered cubic crystal structure. The stability of this phase ranges between 1394 - 1539°C. This is not stable at room temperature in plain carbon steel. However, it can be present at room temperature in alloy steel, especially duple stainless steel.
  • Austenite – Solid solution of carbon in FCC iron formed by solidification of liquid, large grains, and straight grain boundaries, stable at high temperatures. It has high solubility for carbon, high ductility, and formability. It has more solid solubility and density that ferrite. Its single-phase FCC structure is ductile at high temperatures. Large amounts of Ni and Manganese can be dissolved in FFC iron.
  • Cementite – It contains 6.67% carbon by weight, and it is a metastable phase. It is typically hard and brittle interstitial compound of low tensile strength (approx. 5000 Psi) but high compressive strength. It is the hardest structure that appears on the Fe – C diagram. Its crystal structure is orthorhombic.
  • Pearlite – It is composite structure of laminar ferrite and cementite, formed as a product of eutectoid transformation from austenite. It is not a phase but combination of two phases. It has a good, combined strength and toughness and ideal for structural applications.
  • It stands for “Time Temperature Transformation” diagram. It is also called as isothermal transformation diagram and is used for identifying non-equilibrium structures produced in processing at realistic cooling rates.
  • In Fe – C alloys, austenite transforms to martensite on rapid cooling. It is a non-equilibrium structure. It is a diffusion less transformation. Because of the rapid cooling, diffusion is suppressed, and carbon does not partition between ferrite and austenite.
  • Factors affecting TTT diagram are composition of steel (carbon wt%, alloying element wt%), grain size of austenite, heterogeneity of austenite.
  • Heat treatment process is broadly classified as Bulk heat treatment or Through hardening and Surface heat treatment or Case hardening.
  • The various types of heat treatment process that we can undertake for your parts are annealing and normalizing, hardening and tempering, carburizing, nitriding, carbonitriding etc. For more details, please refer the Overview section of this page.
  • Depending on how fast the steel must be quenched, the heat treater will determine the type of quenching required :
    • Air/Gas – It is gentler than oil and has less chance of producing internal stresses, distortion and cracks. It is generally used on steels which have very high alloy content.
    • Water – It is the most used quenching media which is inexpensive and convenient to use. It provides very rapid cooling and can cause internal stresses, distortion, and cracking. It is especially used in low carbon steel which requires a very rapid change in temperature to obtain good hardness and strength.
    • Oil – It is gentler than water and used for critical parts with thin sections and sharp edges such as razor blades, springs, sharp blades etc. It has less chance of producing internal stresses, distortion, and cracking. It is more effective when heated slightly above room temperature.
    • Brine – It is usually made up of 5 to 10% solution of salt in water. It discourages the formation of air globule when it is placed in contact with heated metal. It has the fastest cooling rate and the ability to throw the scale from steel during quenching.
    • Polymer – It is made up of polyvinyl pyrrolidone (PVP) with different concentration in water. It has faster cooling than oil and used for parts which cannot be properly quenched by oil. It can give excellent results on plain carbon and alloy steels that require superior depth of hardness and uniform, repeatable mechanical properties.
  • We have developed and keep upgrading our capabilities by adding professional and experienced vetted suppliers to our vendor network. Please refer to Capability section of this page for more details.
  • Tensile test – It is mechanical testing of a machined or full section specimen under examination to a measured load sufficient to cause rupture and is defined by ASTM E8 – Standard test method for Tension Testing of Metallic Materials. It helps in determining various mechanical characteristics such as ultimate tensile strength, yield strength, elongation, and reduction of area.
  • Hardness test – It is used to determine the ability of a material to resist wear, abrasion, penetration, deformation, and machining. Three commonly used hardness test methods are Brinell hardness, Rockwell hardness and Vickers micro-hardness test.
  • Chemical composition analysis – It is performed using Optical Emission Spectroscopy (OES). A sufficient voltage is induced to produce an arc between a tungsten electrode and the sample to be analyzed. As a result of the burn induced on the sample, light is emitted from the sample. Each element in the sample produces a characteristic wavelength which is measured by the spectrometer. The intensity of each wavelength is directly proportional to the concentration present. Results are displayed in weight percent for each element chosen to be analyzed.
  • Microstructure analysis – This is done to analyze the grain formation and its structure, presence of impurities, porosity, and other microscopic parameters.

Surface Treatment Surface Treatment

  • It is an additional process applied to the surface of a material for the purpose of adding functions such as rust and wear resistance or improving the decorative properties to enhance its appearance.
  • The various types of surface treatment process that we can undertake for your parts are electroplating, anodizing, PVD/CVD, thermal spray coating etc. For more details, please refer the Overview section of this page.
  • We have developed and keep upgrading our capabilities by adding professional and experienced vetted suppliers to our vendor network. Please refer to Capability section of this page for more details.
  • Our coating and plating facility is certified for AS 9100 Rev.D standard and we coat a variety of parts for aerospace, defence and space industry.
  • Jarring mandrels, housings, mud rotors and pistons used in the Oil & Gas industry are coated with carbide and nickel-chrome based coatings to improve its wear, abrasion, and corrosion resistance.
  • Different variants of rolls used in the steel rolling mills are coated with hard chrome and carbide based coatings to improve its sliding wear resistance.
  • A variety of rings, sleeves, shafts, impellers, casings etc. used in the pump assemblies are coated with carbide and cermet coatings to improve its resistance to corrosive and abrasive fluids and gases.
  • Piston rods and cylinders used in compressors and hydraulic assemblies are coated with different ceramic, carbide, and cermet coatings to increase its operational life.

Welding Welding

  • It is a fabrication process whereby two or more parts are fused together by means of heat, pressure or both forming a join as the parts cool. Welding is usually used on metals and thermoplastics but can also be used on wood. The completed welded joint may be referred to as a weldment.
  • Another form of fusing two metals is by form of weld overlay wherein a metal is deposited on substrate by means of welding process. It gives the flexibility of deposit different grades of material over a given substrate.
  • The various types of welding process that we can perform include SMAW, GTAW, PTA, Laser welding, Spray and Fuse etc. For more details, please refer the Overview section of this page.
  • Conventional welding (MIG/TIG)
    • Very widely used in the manufacturing industry
    • Operators are more accustomed with the process
    • It is easier to automate
    • Can be used for welding less precise parts
    • Lower investment costs
  • Laser welding
    • Total heat input is much lower and HAZ (Heat Affected Zone) is much smaller
    • Less thermal stress and damage leading to less distortion
    • Faster production speeds leading to quicker turnaround
    • It is an excellent joining method for thin and delicate parts
  • Welding defects are formed in welding work due to the weak or poor technique used by inexperienced or untrained welders or due to structural problems in the welding operation.
    • Porosity and Blowholes - Porosity is a group of small bubbles and blowholes are relatively large hidden holes or pores mainly caused by trapped gases and weld metal contamination.
    • Cracks – It is the most dangerous type of welding defect. When the weld pool cools and freezes, the weld must be sufficient in volume to overcome the metal shrinkage. Otherwise, it will make a crater crack.
    • Incomplete fusion - These types of welding defects occur when there is a shortage of suitable fusion between the metal and weld. It may also be visible between adjacent weld beads. This produces a gap inside the joint that is not filled with molten metal.
    • Slag inclusion - It can occur when the flux, which is a solid shielding material applied when welding, melts in the weld or on the surface of the weld region. Slag inclusion decreases the strength of the joint and hence makes it weaker.
    • Spatter - Spatters are tiny metal particles that are ejected from the arc during welding and accumulate on the base metal throughout the weld bead along its length. This is particularly common happens in gas-metal arc welding.
    • Distortion - Distortion is the difference in size and location between the positions of the two metal plates before and after welding due to the temperature grade present at several points along the weld joints.
  • We have developed and keep upgrading our capabilities by adding professional and experienced vetted suppliers to our vendor network. Please refer to Capability section of this page for more details.

3D Printing 3D Printing

  • 3D printing, also known as Additive Manufacturing (AM), is a process of making a physical object from a three-dimensional digital model, usually by laying down many successive thin layers of a host of different types of material.
  • It is useful to architects for creating mockups and to mechanics for creating tools. It is used in media houses for manufacturing personalized promo gadgets. It's also a wonderful tool for start-ups when they need to create prototypes of casing or even the casings themselves in low-volume production.
  • Few sectors where 3D printing is being popularly used include medical, architecture, electronics, education, automotive, prototyping, tooling, casting, plastic molding, customized gifting etc.
  • 3D printing can be classified into different types based on the type of material used for manufacturing. The various types of 3D printing methods that can be adopted include Selective Laser Sintering (SLS), Fused Deposition Modelling (FDM), Stereolithography (SLA), Carbon Digital Light Synthesis (DLS), Polyjet, Direct Metal Laser Sintering (DMLS), Metal Binder Jetting etc. For more details, please refer the Overview section of this page.
  • There are a variety of materials that can be 3D print to different geometries of thermoplastic, thermoset and metals. For more details, please refer the Materials section of this page.
  • 3D printing is preferably used for prototyping and new part development due to its ability to print parts with intricate details without the need to invest in dies and tooling’s thereby leading to huge time and cost saving.
  • We can print prototype parts in as less as 5 days after design finalization based on the size, geometry, and complexity of the part.
  • 3D printing poses a variety of applications and advantages when compared to other conventional machining processes. However, it is not an ideal production process for every situation. Below we have listed a few pros and cons which will enable you to make a judicious decision for your requirement.
    • Pros
      • Speed – Unlike conventional manufacturing process, it does not require setup and tooling and hence parts can be made even within a day.
      • Flexibility – It is the most suitable process for making parts which has intricate design. This allows the designer to retain critical features without having to compromise on the functionality.
      • Rapid Prototyping – Due to better speed and flexibility of the process, it is convenient to quickly make changes in the design for optimization.
      • Sustainable – Due to its flexibility for making custom made parts and negligible wastage of input material, the process seems to be more sustainable as compared to traditional manufacturing process.
      • Cost effective – It is economical in most cases as there is no setup time, no tooling, minimal finishing requirement, no input raw material wastage and minimal process monitoring.
      • Durability – 3D printed parts have high impact strength, average flexibility, and high resistance to environmental factors.
      • High precision – The latest advancement in 3D printing technology enables the user to produce parts with high precision and accuracy.
    • Cons
      • Uneven surface finish – Since 3D printed parts consist of multiple layers, there might be visible steps on vertical surfaces which is not aesthetically pleasing. To achieve better surface uniformity and appearance, parts must undergo vapor smoothening.
      • Limited material selection – 3D printing has fewer material options compared to thousands of material options available in the market for casting, forging and injection molding.
      • Size limitation – There can be a constraint in printing extremely small or large sized parts basis the size and selection of the printer.
      • 3D printer limitation – Desktop 3D printers are often built out of a kit and are tuned by hand, which can produce inconsistencies in production.
      • Not ideal for Mass Production – Though 3D printed parts are economical when it comes to lower production volumes and prototyping, it tends to reduce in value when the production requirement crosses more than 100 parts per day. Other processes such as injection molding and die casting provide higher throughput.
  • First layer adhesion problem - This problem refers to a condition where the first layer of the print does not stick to the bed.
    • Check bed levelling – If the bed is not levelled appropriately then the first layer may not stick to the plate.
    • Check bed temperature – Some materials require a heated bed to ensure that the print sticks to the bed.
    • Set optimum print speed – The print speed can significantly affect the layer adhesion. Faster the speed, lower the bed adhesion.
    • Adjust nozzle height - If the nozzle is too high from the bed then the deposited layer will not stick or even fall at the desired location.
    • Use external adhesive agents - If layers are not sticking to the bed, then one solution to ensure proper layer adhesion is to use external adhesive agents like tape, glue or ABS slurry.
  • Nozzle failing to extrude material – This occurs because while the extruder is being heated the material sitting inside starts melting and some of the material starts dripping/oozing down from the nozzle. This causes a void in the nozzle and when the actual print starts, the nozzle does not extrude the material.
    • Ensure priming of nozzle – start all your prints with a few layers of ‘Skirt’ which will help in maintain a regular flow of the material before it starts printing the actual model.
    • Adjust nozzle height – if the nozzle is too close to the build plate, then the extruder may not be able to deposit the required amount of material on to the bed. So, it is important to set the nozzle height appropriately.
    • Check for filament problems – Many times the filaments are not stored appropriately, and this can expose the material to ambient conditions which can deteriorate the material. Sometimes the filament absorbs so much moisture that it forms air bubbles. These air bubbles block the flow and again disrupt the extrusion flow.
  • Weak infill – The infill density and pattern play an important role in the strength of the parts. It also dictates the stability & shape of the model. So, it is important that the infill is carefully selected and used.
    • Set optimum print speed – the infill serves many purposes, and it should be printed with as much precision as the other layers. So, the print speed should be adjusted and generally printed at low speeds. This can be easily resolved through a trial & error method.
    • Check extrusion width – By printing the infill with larger extrusion width, the infill can be substantially stronger. But increasing the infill extrusion width will also increase the amount of material deposited and so if the model is small then the infill pattern may overlap. So, it should be tried only with bigger models.
    • Use appropriate infill pattern – Some infill patterns are stronger than others while others are easy to remove. So, experimenting with the available infill pattern in the slicing software will also help in eliminating the problem of weak infill.
  • Stringing or Oozing – This can be prevented with adequate retraction method. Retraction is the backward movement of the filament to prevent excess oozing of the malted material. By carefully managing this parameter, oozing or stringing problems can be eliminated.
    • Set ideal retraction speed – If the speed is too fast then the melted plastic may break away from the un-melted filament above and the whole purpose of retraction is lost. If the speed is slow, then it may not help in reducing the oozing.
    • Set ideal retraction distance – The retraction distance will depend on the extrusion system, direct-drive, or Bowden-drive. The direct-drive extruders will work with small retraction distances (generally around 1-2mm) while the Bowden extruder system will require retraction distance of around 5-10mm. This distance will also depend on the type of material and the printer used, and so the distance will have to be carefully found out for optimum printing.
    • Adjust heater temperature – If the temperature is too high then the viscosity of the material is lowered and the material drips even when the filament is retracted. A low temperature will stop the oozing but will affect the print quality.
    • Avoid long free travels – By getting into the details of slicer settings the free movement of the nozzle can be controlled. These settings help in finding the shortest route to the next deposition point or the travel movements can be controlled to avoid crossing an open space altogether.
  • Warping – Warping is caused when the deposited material cools quickly. While cooling, the material contracts and this causes the ends to be lifted thereby causing warping. Warping also leads to cracks in the print.
    • Adjust bed temperature – The main solution to eliminating the warping issue is it use a heated bed while printing with materials which undergo warping, namely ABS. The core idea is to keep the first layer heated and not let them cool quickly.
    • Adjust fan speed – Use advanced slicer settings to switch off the fan completely or keep the fan speed to a minimum for the first few layers. The fan can be switched-on after those initial layers.
    • Set optimum ambient temperature - It is advisable to use an enclosure while 3D printing. While an enclosed 3D printer may be costly but this added expense will help to avoid issues like warping, nozzle clogging, etc.
    • Try new build plates - To increase the build adhesion between the layers and the build plate, new types of build surfaces and plates can be used.
  • During a 3D printing process, specifically SLM method, the atmosphere that surrounds the powder used for printing can oxidize which alters its melting point and warps the printed part.
  • The 3D printing process is like welding wherein the fusing takes place in inert atmosphere of argon or helium to ensure that oxygen does not contaminate the process. Even tiny amounts of oxygen can lead to change of color and physical properties of the part.
  • One primary advantage of post-printing heat treatment is its de-tensioning effects. During the printing phase, materials can accumulate internal stresses and tensions, which compromise mechanical properties – weaknesses that heat treatment can reverse.
  • It can be used to optimize the properties of printed products, adding extra features such as heat resistance or tensile strength. Vacuum heat treatment offers the best performance for post-printing heat treatment.
  • Use of vacuum minimizes the degree of surface contamination detected following 3D printing, improving the physical performance of components. It also enables technicians to carry out accurate, easily repeatable corrosion tests on printed components. It can also have aesthetic benefits for printed parts.

Testing and Assembly Testing and Assembly

  • We provide a variety of testing services, few of which are performed in-house and few outsourced to our qualified service providers. Outsourced test laboratories are NABL accredited and periodically audited for conformance to international standards. For more details, please refer the Testing section of this page.
  • The testing of final part or assembly is utmost important to validate and approve. Testing requirements are reviewed for feasibility during the RFQ stage.
  • Initial and intermediary tests such as raw material chemical and mechanical testing, dimensional and NDT are identified at every stage and performed as per specifications provided by the client.
  • Functional and Performance based tests of the final part/assembly will however depend upon the overall scale and scope of the project. We can make customized test rigs and fixtures to simulate the actual testing conditions as required by the client and provide certified test results.
  • The inspections and tests carried out at every stage as per QAP, is recorded in our DMS (Data Management System).
  • The test certificates mandated by the client are identified and listed during our internal review process. Standard to be followed for testing and information to be displayed on the certificate is also noted.
  • The test certificates are submitted to the client at intermediary and final stage for review and approval. The parts are packed and shipped only post clearance from the client.