Manufacturing Industry Glossary of Terms

A

Ablation

The removal of material from a surface by vaporization, chipping, or erosive processes. Critical in aerospace applications where materials experience extreme temperatures during atmospheric reentry.

Adhesion

The ability of a material to stick to another material, critical for gaskets and other bonded components.

AS9100

An aerospace-specific quality management system standard based on ISO 9001, with additional requirements for quality and safety in the aerospace industry.

Assembly

The systematic process of combining multiple manufactured components into a complete or semi-complete product. Assembly operations can range from manual procedures to fully automated systems, often incorporating fixtures, jigs, and specialized tools to ensure proper alignment and connection of parts. In precision manufacturing for aerospace and medical industries, assembly may include critical processes such as clean room assembly, torque-controlled fastening, precision alignment, testing, and validation. Assembly operations are often guided by detailed work instructions and may require specialized training, particularly for components involving EMI shielding, hermetic sealing, or critical tolerance stack-ups that affect system performance.

Attenuation

The reduction in amplitude or energy of a signal as it passes through a material. In RF/EMI shielding, attenuation refers to how effectively a shield reduces the strength of electromagnetic waves.

B

Bead Size

The dimensional specifications of a dispensed gasket, typically referring to the height and width of form-in-place (FIP) gaskets. Bead size affects compression force requirements, sealing effectiveness, and material usage. For RF/EMI shielding applications, precise bead size control is critical to maintain optimal electrical conductivity while ensuring proper compression.

Board Shield

A small RF shield designed to protect specific components on circuit boards from electromagnetic interference.

Beryllium Copper

A copper alloy containing beryllium that exhibits high strength, good electrical and thermal conductivity, and excellent formability.

C

CMM (Coordinate Measuring Machine)

A precision measuring instrument that uses a probe to detect discrete points on a workpiece surface in three-dimensional space. CMMs provide highly accurate measurements of physical geometrical characteristics with precision typically in the micron range. These machines are critical for quality control in manufacturing, allowing for verification of part dimensions against design specifications. Modern CMMs often include touch-trigger probes, optical sensors, or laser scanners, and can be programmed for automated measurement sequences of complex geometries.

CNC Cutting

A computer-controlled cutting process that uses various cutting tools or methods (such as knife, router, or laser) guided by precise digital instructions to cut materials into specified shapes. This technique allows for accurate replication of intricate patterns and designs across multiple production runs, with minimal material waste and high repeatability. CNC cutting is commonly used for soft materials like foams, rubbers, and fabrics when precise, complex cuts are required.

CNC Machining

Computer Numerical Control manufacturing that uses computerized controls to operate machine tools (mills, lathes, routers, grinders) with precision. This process can produce complex three-dimensional shapes with tight tolerances from metals, plastics, and composites. CNC machining offers high repeatability, flexibility for design changes, and the ability to create parts that would be difficult or impossible to make using manual methods.

Coefficient of Thermal Expansion (CTE)

The rate at which a material expands or contracts in response to temperature changes. Mismatched CTEs between joined materials can lead to mechanical stress and failure at interfaces.

CMMC (Cybersecurity Maturity Model Certification)

A unified standard for implementing cybersecurity across the defense industrial base.

Compression Set

A measure of a material's ability to return to its original thickness after being compressed for a specific time period, critical for gasket performance.

Compression Stops

Design features used instead of grooves to control gasket height in FIP applications. These mechanical features prevent over-compression of gaskets and ensure proper sealing force. Compression stops allow for more consistent gasket performance compared to dispensing into grooves, as they prevent asymmetrical curing that can occur when gasket material contacts groove walls.

Conductivity

A material's ability to transmit energy:

• Electrical Conductivity - The ability to conduct electrical current, measured in Siemens per meter (S/m).
• Thermal Conductivity - The ability to conduct heat, measured in Watts per meter-Kelvin (W/m·K).

Conductive Filler

Materials added to elastomers to make them electrically conductive, commonly used in EMI/RFI shielding gaskets. Common fillers include silver, silver copper, silver nickel, silver aluminum, nickel graphite, and nickel aluminum. The choice of filler affects conductivity, corrosion resistance, galvanic compatibility, and cost.

Curing

The process by which a liquid or semi-liquid material chemically changes to become a solid. For FIP gaskets, curing can occur through heat (thermal cure), moisture exposure, or UV light. The curing method and surrounding environment (including proximity to ferrous materials) can significantly affect final gasket properties and performance.

D

Design for Manufacturability (DFM)

The practice of designing products with manufacturing capabilities and limitations in mind.

Die Cutting

A process that uses metal dies to cut specific shapes from sheet materials like elastomers or foams.

Digital Cutting

A computer-controlled cutting process that uses programmed patterns to precisely cut materials without requiring hard tooling. Digital cutting offers flexibility for design iterations, minimal waste, and the ability to cut complex shapes with tight tolerances. Unlike die cutting, digital cutting is ideal for prototyping and low to medium volume production runs where design changes are frequent.

Dispense Path

The predetermined route that a form-in-place gasket material follows when applied to a housing or component. An optimal dispense path minimizes starts, stops, and intersections while maintaining consistent wall thickness for the gasket material to adhere to.

Durometer

A measurement of the hardness of a material, particularly elastomers, usually expressed in Shore A or Shore D scales.

E

Edge Break

A design feature that removes the sharp edges from a machined part, typically specified rather than modeled as chamfers. Properly specified edge breaks prevent operator errors during machining and reduce the risk of part damage or user injury from sharp edges.

Elastomer

A polymer with viscoelasticity, generally low Young's modulus, and high yield strain compared with other materials.

EMI (Electromagnetic Interference)

Disturbance that affects electrical circuits due to electromagnetic radiation emitted from an external source.

Electrostatic Discharge

Electrostatic discharge is the sudden transfer of electrical charge between objects at different electrical potentials, often occurring when accumulated static electricity seeks a path to ground. This rapid discharge can generate voltages exceeding thousands of volts and can destroy sensitive electronic components, corrupt data, or ignite flammable materials in critical applications.

EMI Shielding

Materials and structures designed to block or attenuate electromagnetic interference (EMI) from affecting sensitive electronic components or systems. EMI shielding works through reflection and absorption of electromagnetic energy, preventing it from entering or exiting protected areas. Effective EMI shields typically use conductive materials (metals, metallized fabrics, or conductive elastomers) that create a Faraday cage effect. Shielding effectiveness is measured in decibels (dB) of attenuation across specific frequency ranges, with aerospace and defense applications often requiring 90-100+ dB of protection.

Emissivity

Similar to thermal emittance, it's the ratio of energy radiated from a material's surface to the energy radiated from a perfect blackbody at the same temperature. Critical for thermal control in space applications.

Environmental Seal

A specialized barrier designed to protect enclosed components from external environmental factors such as moisture, dust, chemicals, pressure differentials, and temperature extremes. Environmental seals create controlled internal environments for sensitive electronics, mechanical systems, and optical components, preventing contamination and degradation. These seals must maintain their integrity across specified temperature ranges, pressure conditions, and exposure to various chemicals or UV radiation. In aerospace, defense, and medical applications, environmental seals often require certification to industry standards such as IP (Ingress Protection) ratings, NEMA classifications, or military specifications to ensure reliable performance in challenging operational environments.

Extrusion

A manufacturing process that forces material through a die to create objects with a fixed cross-sectional profile. The material, typically heated to increase formability, is pushed or drawn through the die opening and then cooled to maintain the desired shape. Common extruded materials include thermoplastics, elastomers, metals, and ceramics. Extrusion enables the production of continuous lengths of complex profiles with consistent dimensions, making it ideal for creating gaskets, seals, thermal management components, and structural elements. Co-extrusion techniques can combine multiple materials in a single operation to create products with varying properties across their cross-section, such as gaskets with rigid backing and soft sealing surfaces.

F

Faraday Cage

An enclosure used to block electromagnetic fields, made from conductive materials.

Far-Field Testing

A method for measuring electromagnetic interference at distances where the radiation pattern doesn't change shape with distance. Used to evaluate shielding effectiveness of larger assemblies.

FIP (Form-in-Place) Gasket

A liquid gasket material that is dispensed directly onto a part and then cures in place to form a custom gasket.

Five-axis Milling Machine

A CNC machine tool that features five axes of motion (three linear axes: X, Y, Z, plus two rotational axes), allowing the cutting tool to approach the workpiece from virtually any direction. This capability enables machining of complex contoured surfaces and undercuts in a single setup, which would be impossible on conventional three-axis machines. Five-axis machining reduces setup time, improves accuracy by eliminating multiple setups, and allows for the creation of complex aerospace, medical, and defense components with superior surface finishes.

G

Galvanic Compatibility

The ability of dissimilar metals to be in contact without causing accelerated corrosion due to galvanic reactions. When designing parts that incorporate different metals, galvanic compatibility must be considered to prevent premature degradation, particularly in aerospace and defense applications where reliability is critical.

Galvanic Corrosion

An electrochemical process where one metal corrodes preferentially when in electrical contact with another metal in the presence of an electrolyte.

Gasket

A mechanical seal that fills the space between two or more mating surfaces to prevent leakage of fluids or gases while under compression. Gaskets compensate for imperfections in mating surfaces and maintain sealing integrity despite thermal expansion, vibration, and pressure fluctuations. Materials used for gaskets vary widely based on application requirements and include elastomers (silicone, EPDM, fluorosilicone), compressed fiber materials, metals, and various composites. For critical applications in aerospace and medical devices, gaskets may incorporate multiple design features such as environmental sealing, EMI shielding, vibration damping, and thermal management. Gasket performance is characterized by compression set resistance, chemical compatibility, temperature range, flammability rating, and longevity under cyclic loading conditions.

H

Hardness

A measure of a material's resistance to permanent deformation when a force is applied. Various scales and testing methods exist depending on the material type:

• Shore Hardness - Used primarily for elastomers and soft polymers:
  • Shore A scale (0-100): For softer materials like silicone gaskets and rubber. Higher numbers indicate harder materials (typical gasket materials range from 20-80 Shore A).
  • Shore D scale (0-100): For harder elastomers and semi-rigid plastics.
• Rockwell Hardness - Used for metals and harder plastics:
  • Scales include A, B, C, with Rockwell C (HRC) commonly used for harder metals.
• Brinell Hardness (HB) - Used for ferrous and non-ferrous metals, employing a hardened steel ball pressed into the material surface.
• Vickers Hardness (HV) - Used for a wide range of materials, using a diamond pyramid indenter.

Hardness affects material performance characteristics including wear resistance, flexibility, compression set, and durability. In gasket applications, hardness impacts sealing performance, compression force requirements, and ability to conform to surface irregularities.

Heat Sink

A passive thermal management component designed to absorb and dissipate heat away from critical electronic components. Heat sinks typically feature extended surfaces (fins) that increase the surface area available for heat transfer to the surrounding environment. The effectiveness of a heat sink depends on its material (commonly aluminum or copper for high thermal conductivity), surface area, airflow, and interfacial thermal resistance. Proper design considers fin height, spacing, thickness, and base thickness to optimize thermal performance while meeting size and weight constraints.

Horizontal Milling Machine

A CNC machine tool configuration where the main spindle is oriented horizontally, parallel to the work surface. This arrangement provides superior support for the cutting tool, reducing deflection and enabling heavier cuts compared to vertical machines. Horizontal mills excel at machining large, heavy workpieces and complex prismatic parts, offering improved chip evacuation and the ability to machine multiple sides of a part in a single setup using a rotary table. They are particularly valuable for production environments requiring high metal removal rates and complex features on multiple faces of a part.

I

ISO 9001

An international standard that specifies requirements for a quality management system.

ITAR (International Traffic in Arms Regulations)

U.S. regulations that control the export and import of defense-related articles and services.

L

Laminating

The process of bonding two or more layers of materials together to create a composite with enhanced properties. Lamination can combine different materials (such as films, fabrics, foams, adhesives, or metals) to achieve specific mechanical, thermal, electrical, or barrier characteristics that a single material cannot provide. Common lamination methods include adhesive bonding, heat fusion, and pressure bonding. In aerospace and medical applications, laminated materials are crucial for creating lightweight, multifunctional components with precise performance characteristics such as EMI shielding combined with thermal insulation or structural support.

Laser Profilometer

A non-contact measuring instrument that uses laser technology to precisely measure surface profiles, dimensions, and textures. Laser profilometers project a laser line onto a surface and capture its reflection with a detector to create a high-resolution topographical map. These devices can measure features as small as nanometers with high speed and accuracy, making them ideal for inspecting critical surface characteristics, flatness, roughness, and waviness in precision-manufactured components. Particularly valuable for quality control in medical device and aerospace applications where surface integrity is critical.

Laser QC Machine

A quality control device that uses laser technology to verify part dimensions, shapes, and positions with high precision and speed. Laser QC machines can scan parts and compare measurements to CAD models or specifications to identify deviations. These systems offer non-contact measurement, eliminating the risk of part damage during inspection while providing highly accurate and repeatable results. Particularly useful for inspecting complex geometries, fine features, and form-in-place gasket dimensions that might be difficult to measure with traditional contact methods.

Lead Time

The time between the initiation and completion of a production process.

M

Material Compatibility

The ability of different materials to coexist without adverse chemical or physical interactions that would degrade performance or reliability.

Microwave Absorption

The process by which materials convert microwave energy into heat through dielectric or magnetic losses. Specialized microwave absorber materials are designed to attenuate electromagnetic waves in specific frequency ranges, typically from 500 MHz to 40+ GHz. These materials eliminate signal reflections, reduce electromagnetic interference, and control RF environments in sensitive electronic applications. Common in defense, aerospace, telecommunications, and medical equipment where precise control of electromagnetic environments is critical.

MIL-SPEC (Military Specification)

A set of standards issued by the U.S. Department of Defense for military and defense-related equipment and processes.

Molding

A manufacturing process that shapes materials by forcing them into a mold cavity where they solidify into the desired form. Common molding techniques include injection molding (for thermoplastics), compression molding (for thermosets), and transfer molding (for rubbers and silicones). The process allows for high-volume production of complex parts with consistent dimensions and surface finishes. In precision applications, molding can incorporate inserts and create intricate features that would be difficult to achieve with other manufacturing methods. Medical and aerospace industries often use specialized molding processes with high-performance materials to create critical components with tight tolerances.

N

Near-Field Testing

A method for measuring electromagnetic interference at distances close to the source where the radiation pattern changes with distance. Used for evaluating component-level shielding.

O

O-Ring

A mechanical gasket in the shape of a torus, designed to be seated in a groove and compressed during assembly to create a seal.

Optical Coating

A thin layer or multiple layers of material applied to an optical component to alter its reflective properties. These coatings can enhance reflection, reduce reflection (anti-reflective coatings), filter specific wavelengths, or provide protection against environmental factors. Optical coatings are typically applied through vapor deposition processes and can range from nanometers to micrometers in thickness. Applications include optics for aerospace sensors, medical imaging devices, and defense optical systems where precise control of light transmission and reflection is critical.

Outgassing

The release of gas that was dissolved, trapped, frozen, or absorbed in a material. Critical in aerospace, vacuum, and medical applications where released volatiles can contaminate sensitive surfaces or environments. Materials with low outgassing properties are essential for space applications, optical equipment, and certain medical devices.

P

Passive Thermal Control

Systems that regulate temperature without requiring power or moving parts, relying instead on material properties like solar reflectance and thermal emittance.

Particulate Loading

The process of adding particles to a base material to achieve specific properties, such as electrical conductivity or thermal conductivity.

Permeability

In electromagnetic contexts, a material's ability to support the formation of a magnetic field. Materials with high magnetic permeability are used for magnetic shielding.

Plating

The process of covering a metal component with a thin layer of another metal to improve properties such as conductivity, corrosion resistance, wear resistance, or aesthetic appearance. Common plating materials include nickel, silver, gold, copper, and zinc. In EMI/RFI shielding applications, conductive plating is essential for creating continuous electrical pathways that prevent signal leakage.

PSA (Pressure Sensitive Adhesive)

A non-reactive adhesive that forms a bond when pressure is applied, requiring no chemical reaction, heat, or solvent to activate its adhesive properties. PSAs remain permanently tacky at room temperature and adhere to surfaces with light pressure. They are commonly used in tapes, labels, and pre-applied adhesive systems for gaskets and thermal interface materials. The performance of PSAs is characterized by their adhesion strength, cohesive strength, temperature resistance, and aging properties. In aerospace and medical applications, specialty PSAs are formulated to maintain bond integrity under extreme temperatures, resist outgassing in vacuum environments, and provide electrical conductivity or thermal transfer when required.

Prototype

An early sample, model, or release of a product built to test a concept or process.

Q

Quality Management System (QMS)

A formalized system that documents processes, procedures, and responsibilities for achieving quality policies and objectives.

R

RF Leakage

The unintended emission or penetration of radio frequency electromagnetic energy through gaps, seams, or imperfections in shielded enclosures or cable systems. RF leakage can occur at connector interfaces, housing seams, ventilation openings, or any discontinuity in a shielding system. This phenomenon can compromise the integrity of sensitive electronic equipment, lead to data security vulnerabilities, or cause regulatory compliance failures. The severity of RF leakage is typically measured in decibels (dB) as a deviation from ideal shielding effectiveness. Mitigation strategies include conductive gaskets, proper torque of fasteners, overlapping shield designs, and careful attention to surface conductivity at mating interfaces. In aerospace, defense, and medical applications, RF leakage testing is often performed as part of quality control to ensure systems maintain specified shielding levels throughout their operational lifecycle.

RF (Radio Frequency) Shielding

Materials used to reduce or block radio frequency electromagnetic radiation.

RFI (Radio Frequency Interference)

Electromagnetic interference within the radio frequency spectrum.

S

Shielding Effectiveness (SE)

A measure of how well a material blocks electromagnetic fields, typically expressed in decibels (dB). Higher dB values indicate better shielding performance. Factors affecting shielding effectiveness include material conductivity, thickness, frequency of the interfering signal, and any apertures or seams in the shield. In aerospace and defense applications, shielding effectiveness of 90-100+ dB is often required.

Shore A

A scale used to measure the hardness of elastomers, with higher numbers indicating harder materials.

SigShield™

Modus Advanced's proprietary vertically integrated process for manufacturing RF shields, which includes metal housing machining, form-in-place gasket dispensing, plating, and the addition of thermal materials and RF absorbers under one roof to reduce lead times and improve quality.

Silicone

A polymer made up of siloxane, used in gaskets, thermal management, and other applications due to its temperature resistance and flexibility.

Slitting

A continuous process that cuts larger rolls of flexible materials into narrower widths or specific shapes. Slitting equipment uses rotary knives, razor blades, or laser beams to create precise, clean cuts with minimal edge deformation. This process is essential for converting large master rolls of materials such as films, foils, fabrics, and adhesives into specific widths required for various applications. Precision slitting is critical in manufacturing thermal interface materials, EMI shielding tapes, and multi-layer insulation where dimensional accuracy and edge quality directly impact performance and assembly.

Soft Goods Converting

The process of transforming flexible materials such as fabrics, films, foams, and elastomers into custom-engineered components. This includes cutting, laminating, die-cutting, and finishing operations to create components that meet specific design requirements. Commonly used in aerospace, defense, and medical applications where specialized materials need to be precisely fabricated into components like gaskets, seals, insulators, and protective covers.

Solar Absorptance (α)

The fraction of incident solar radiation that is absorbed by a material's surface. Values range from 0 to 1, with higher values indicating greater absorption of solar energy. This property is critical in spacecraft thermal control systems and passive building design. Materials with high solar absorptance will convert more solar radiation into heat.

Solar Reflectance (ρ)

The fraction of incident solar radiation that is reflected by a material's surface. Values range from 0 to 1, with higher values indicating better reflection of solar energy. The sum of solar absorptance, reflectance, and transmittance equals 1. Solar reflectance is particularly important in aerospace thermal management and energy-efficient building materials.

Sound Dampening

The reduction of noise and vibration through materials that absorb acoustic energy and convert it to heat. Sound dampening materials typically feature viscoelastic properties that dissipate vibration energy. These materials may be incorporated into multilayer constructions with constraining layers to enhance performance. Common applications include aerospace cabins, medical equipment enclosures, and electronic housings where unwanted noise must be controlled without adding significant weight or bulk.

Static Dissipation

Static dissipation is the controlled process of safely removing accumulated electrical charges from surfaces or materials to prevent sudden electrostatic discharge events. This gradual charge removal protects sensitive electronic components from damage while maintaining safe operating conditions in critical applications.

Static Dissipative Materials (ESD Materials)

Static dissipative materials are engineered substances with electrical resistance between 10⁶ to 10⁹ ohms that allow electrical charges to flow slowly and in a controlled manner to ground. These materials provide the optimal balance between rapid conductive discharge and charge-trapping insulative behavior, making them ideal for protecting sensitive electronics in aerospace, defense, and medical device applications.

Strategic Sourcing

A procurement methodology focused on creating long-term cost savings and improved strategic relationships with suppliers.

Surface Resistivity

A measure of the electrical resistance of a material's surface, typically expressed in ohms per square. Important for EMI shielding and static discharge applications.

T

Thermal Control Coating

Surface treatments applied to materials to regulate temperature by controlling solar absorptance (α) and thermal emittance (ε). These coatings can be designed to have specific α/ε ratios for optimal thermal management in various environments. Low α/high ε coatings keep surfaces cool in solar exposure, while high α/low ε coatings help retain heat. Aerospace applications use these coatings extensively for passive thermal control of spacecraft components. Common types include white paints (low α/high ε), black paints (high α/high ε), and metallized films (low ε) for thermal isolation.

Thermal Cycling

The process of alternating exposure to hot and cold temperatures to test material durability and bond integrity. Critical for aerospace components that experience extreme temperature variations.

Thermal Conductivity

A measure of a material's ability to conduct heat, important in thermal management applications.

Thermal Emittance (ε)

The relative ability of a material's surface to emit energy by radiation. Values range from 0 to 1, with higher values indicating greater emissive power. Materials with high thermal emittance cool more effectively by radiating heat away. This property is particularly important in spacecraft thermal control systems where radiation is the primary means of heat transfer. The ratio of solar absorptance to thermal emittance (α/ε) is a critical design factor for passive thermal control in space environments.

Thermal Interface Material (TIM)

Materials designed to improve thermal coupling between heat-generating components and heat sinks by filling air gaps.

Thermal Management

The practice of controlling temperature in devices through various means, including heat sinks, thermal interface materials, and fans.

V

Vent Shield

A specialized RF shield that allows air to flow through while blocking electromagnetic signals, commonly used in electronics that require both cooling and RFI protection.

Vertical Integration

A manufacturing strategy where multiple production processes (such as machining, plating, gasket dispensing, and assembly) are performed by a single manufacturer, eliminating shipping between vendors and reducing lead times while maintaining consistent quality control.

Vertical Milling Machine

A CNC machine tool configuration where the main spindle is oriented vertically, perpendicular to the work surface. This orientation allows for direct overhead access to the workpiece, making it ideal for face milling, profiling, drilling, and 2.5D/3D contouring operations. Vertical mills typically offer good visibility of the cutting process and are more compact than horizontal configurations, making them suitable for shops with space constraints. They excel at producing parts with features primarily on one side and are widely used for prototyping and lower-volume production runs due to their versatility and ease of setup.

Vibration Isolation

The process of preventing vibration transmission between structures using specialized materials or mechanical systems. Vibration isolators reduce the transfer of mechanical energy by converting kinetic energy into heat or by redirecting forces through carefully designed components. Common isolation methods include elastomeric mounts, wire rope isolators, air springs, and viscoelastic dampers. In precision applications, vibration isolation protects sensitive equipment from operational vibrations, external disturbances, and shock events that could affect performance, accuracy, or component lifespan. Design considerations include natural frequency, dynamic stiffness, load capacity, and environmental stability. Aerospace and medical systems often require customized isolation solutions that maintain precise performance characteristics across wide temperature ranges and throughout long service lives.

Vision System

An automated optical inspection technology that uses cameras, lighting, and image processing software to examine, measure, and verify parts against predetermined specifications. Vision systems can detect defects, verify dimensions, read barcodes or text, and inspect surface quality at high speeds with sub-micron accuracy. These systems excel at non-contact measurement of small, delicate parts or features that would be difficult to measure with conventional tools. In manufacturing environments, vision systems are critical for in-line quality control, providing 100% inspection capabilities rather than sampling, thereby reducing the risk of defective parts reaching customers.

Volume Resistivity

A measure of how strongly a material opposes the flow of electric current, measured in ohm-cm.

W

Waterjet Cutting

A manufacturing process that uses a high-pressure jet of water, or water mixed with an abrasive, to cut materials.