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Roll forming is a high-volume production process used to produce an unlimited variety of formable cross-sections. Through the use of shop floor footage and detailed animations, this Roll Forming program highlights in detail: roll forming dimensional tolerances, material straightness, camber, curve, bow & twist, roll form tooling, and roll forming machines.

The Roll Forming Machines segment explores outboard spindle support, single-duty machines, conventional machines, side-by-side machines, double head machines, rafted machines, drive mechanisms, and the use of lubricants.

The Thermal & Electro-Chemical Deburring segment features a detailed examination of thermal energy deburring, and electro-chemical deburring.

Workholding includes any device used to grip and present a workpiece to a cutting tool on a machine tool. To provide an understanding of workholding as a fundamental issue in the machining process, this Workholding program examines the principles of workholding, milling & machining center workholding, and lathe workholding. The Principles of Workholding segment covers datums, part location, the six degrees of freedom, the 3-2-1 locational method, and issues of reclamping or rechucking workpieces. The Milling & Machining Center Workholding segment looks at small-lot, medium-lot, and mass-production workholding options while detailing the use of clamps, vises, multi-vises, cubes, columns, tombstones, indexers, rotary tables, modular fixturing, pallets, pneumatic clamping, hydraulic clamping, vacuum workholding, and application-dedicated fixtures. The Lathe Workholding segment explores the use of 3-jaw chucks, 6-jaw chucks, 4-jaw chucks, 2-jaw chucks, indexing chucks, collets, collet chucks, between centers turning, drive dogs, face drivers, steady rests, and magnetic chucks and fixtures.

The Injection Mold Types segment showcases in detail the cold-runner two-plate mold, the cold-runner three-plate mold, the hot-runner mold, and the insulated runner mold.

The Plastics Assembly section covers the many fastening and joining methods used to produce plastic parts. Included are segments on snap-fit fasteners, the use of hinges, mechanical fasteners, adhesive and solvent bonding applications, and the various plastic welding processes, including: spin welding, hot-gas welding, ultrasonic welding, vibration welding, heat staking and ultrasonic staking.

Plating and surface coating processes are used throughout manufacturing to provide protection, durability and decoration to parts. This program explains and highlights the use of electroplating, electroless plating, conversion coating, hot dipping, and porcelain enameling.

This Pultrusion program details the high-throughput, continuous pultrusion process. The reinforcement materials used to produce pultrusions are followed step by step through the process - from resin saturation and impregnation, preforming, shaping, curing, and cut-to-length sawing. This program is part of an eight program Composites Manufacturing series.

The Injection Mold segment details and defines mold terms as the molten thermoplastic material is formed, cooled, and ejected as a final part. Also featured are the common mold types, including the two-plate cold runner mold, three-plate cold runner mold, the hot runner mold, and the insulated runner mold.

Datums are reference measurement surfaces, planes, or points from which other part features are measured. By using the 14 geometric characteristic symbols along with datum references the functional requirement of a part or assembly can be effectively communicated. The proper identification and usage of datums in GD&T is explored.