Nontraditional metal fabrication machining processes are those that are new to the industry and do not always use machining forces and perishable tooling. These nontraditional processes often advance the metal fabrication industry by making it possible to cut materials that were formerly too difficult or impossible to work with. Some of these processes are becoming more widely used in the metal fabrication industry.

Abrasive Flow Machining

Abrasive flow machining is a complex process that directs a semisolid abrasive material back and forth between two opposing cylinders with block or sheet metal positioned in between. This process cuts through metals made of soft aluminum and nickel alloys.

Another form of metal fabrication processing using abrasive flow technology is abrasive jet machining. This process uses the same abrasive material, propelled at the metal at high velocities using a directed stream of compressed air or CO2. This is highly effective in deburring, cleaning and cutting parts. The abrasive materials can consist of silicon carbide, aluminum oxide, boron carbide or glass beads. The added use of compressed gas helps to keep the materials and the working environment cool during processing.

Laminated Object Manufacturing

The laminated object manufacturing metal fabrication process produces models from solid sheet materials. Solid sheet materials can be purchased in bulk and are cheaper than other types of production materials. The process uses a three dimensional electronic file and laser applications to create the machining effect. Drilling, welding, engraving and case-hardening can all be completed using these lasers. Intense pulsed beams of light created by carbon dioxide lasers are often used. Compressed air, argon, oxygen and nitrogen are also used in laminated object manufacturing.

Reverse Engineering

Reverse engineering is a metal fabrication process that utilizes lasers, CMM and other measuring devices to create a computer assisted design file from an existing part. This 'scanning' of an existing part allows the operator to precisely reproduce the existing part, repair any flaws by altering the production of the new part or to redesign an entirely new part based on the substructure of the scanned part. It is a very useful nontraditional process for companies that develop new parts and seek to improve on existing designs.

Thermal Energy Finishing

Thermal energy finishing uses thermal energy and the resulting heat to quickly and accurately burn away the unwanted flash material and burrs from around finished parts. This finishing process is ideal for use with parts that are used to conduct fluids or gases. It also consistently produces a quality product that is free of contaminates. This in turn reduces the need for wasted metal fabrication materials due to inaccurate parts and eliminates the need for extensive quality control checks.