What is Precision Engineering?

Precision Engineering is a subdiscipline of mechanical, electrical, optical, and software engineering concerned with manufacturing, inspection (i.e., metrology), and the design of machines, instruments, optical systems, fixtures, and other structures and systems that have exceptionally low tolerances, are repeatable, and stable over time [1]. Typically, its work at the forefront of current technology, implicitly in the fields of metrology and advanced manufacturing technology where tolerances are smaller than 1 part in 104 or perhaps 105 [2]. The field does not focus only on the absolute scale of a product or process, it also considers the ratio of a product's or process's overall dimensions to the smallest change or uncertainty in position or dimensions of components that are operationally significant [3]. Ultimately, the goal of precision engineering and design is to create a process for which the outcomes are deterministic and controllable over a range of operation, with unpredictable deviations from a desired result being as small as is physically and economically possible [4]. For many new products, today's precision engineering is of prime economic importance. In many areas, the precision engineering of today will be the general engineering of tomorrow [2].

The above is a reproduction/compilation of statements/quotes from some of the sources cited below. To obtain a more in-depth understanding of precision engineering and what it entails, a review of the cited sources is highly recommended.

Personally, we like to think of Precision Engineering as a state of mind. A mindset, that believes anything can influence the overall performance of a design and/or process and all possible contributors should be considered. A Precision Engineer is a determinist who applies a collection of precision methodologies and tools to improve products and processes. The same skillset and tools can be applied to any product or process, whether precise or conventional, to facilitate improvement.

Although a complete definition of precision engineering does not exist, it can be easily stated that almost all professional senior level precision engineers maintain, expand, and practice a specific set of methodologies and a body of knowledge. Examples of which are listed below.

Fundamental Methodologies Practiced by Precision Engineers

In the field of precision, engineers and technicians practice many core fundamental methodologies. These methodologies include, but are not limited to:

  • Deterministic thinking
  • System error budgeting & modeling
  • Thermal management & design
  • Structural loops: force vs metrology
  • Vibration mitigation & analysis
  • Material selection
  • Environmental considerations
  • Exact constraint vs elastic averaging
  • Symmetry vs asymmetry
  • Occam's razor (simple is better)
  • Stiffness (minimizing joints and moments)
  • Null control
  • Error separation - Reversals
  • Abbe & Cosine errors
  • Measurement uncertainty
  • Error mitigation
  • Foundations of mechanical accuracy
  • Precision technology components
  • Geometric Dimensioning & Tolerancing
  • Tolerance stack-up

Precision Manufacturing & Assembly

In precision manufacturing, precision engineers and technicians are very knowledgable about:

  • Precision manufacturing systems & their capabilities
  • Form & finish and achieving form & finish requirements
  • Achieving tolerances less than 1:103
  • Achieving surface finish < 1 μm Sq
  • Mechanical accuracy & implementation

Precision Equipment Design

In the design and building of equipment, precision engineers and technicians are have the skills to:

  • Design and build systems, machines, & instruments with repeatabilitis & resolutions less than 1:104 & 1:105, respectively
  • System integration for higher precision
  • Design and/or select precision components

Precision Control

In machine and instrument control, precision engineers and technicians are knowledgable about and practice:

  • Profile generation & loop shaping
  • High precision control (motion, force, dynamic, & environmental)
  • Real-time control & open architecture
  • Dynamic error budgeting
  • Understanding of sensor response

Precision Metrology

In the field of precision metrology, engineers and technicians are knowledgable about and practice:

  • Workpiece inspection & characterization
  • Machine error characterization
  • Error compensation & correction
  • Instrument & sensor calibration
  • Measurement uncertainty
  • High precision instrumentation and sensor technologies

Finite Elemental Analysis

To better understand processes and to help predict the performance of precision systems and process, engineers and technicians work with commerically available simulation software and/or develop custom simulation applications to perform and/or simulate:

  • FEA as applied to precision engineering
  • Cutting mechanics
  • Thermal
  • Dynamics
  • Vibration
  • Stress & Strain
  • Fluid Dynamics

State of the Art Linkages

Because precision engineering is a relatively small field, its important for engineers and technicians to share knowledge and experiences. We do this by participating in both acedemic centers and professional organizations. Examples include, but are not limited to:

Precision Engineering References

  1. Precision engineering. (2019). In Wikipedia. https://en.wikipedia.org/wiki/Precision_engineering
  2. McKeown, P. A. (1987). The Role of Precision Engineering in Manufacturing of the Future. CIRP Annals - Manufacturing Technology, 36(2), 495–501
  3. Jones, R. V. (1979). Precision engineering from supertankers to integrated circuits. Precision Engineering, 1(1), 3
  4. Leach, R., & Smith, S. T. (Eds.). (2018). Basics of Precision Engineering (1 edition). Boca Raton: CRC Press.
  5. McKeown, P. A. (1979). Why precision? Precision Engineering, 1(2), 59
  6. Taniguchi, N. (1983). Current Status in, and Future Trends of, Ultraprecision Machining and Ultrafine Materials Processing. CIRP Annals - Manufacturing Technology, 32(2), 573–582.