Designing a Modular Rapid Manufacturing Process

Abstract

Freeform fabrication and additive fabrication technologies have been combined with subtractive processes to achieve a variety of fully integrated rapid manufacturing systems. The combination of separate fabrication techniques into one rapid manufacturing system results in unit manufacturing process integration, sometimes known as a hybrid system. However, the design methods or approaches required to construct these integrated systems are vaguely described or not mentioned at all. The final product from any integrated system is affected not only by the unit manufacturing processes themselves, but also by the extent the individual units are assimilated into an integrated process. A wide variety of integrated and hybrid manufacturing systems and current manufacturing design methodologies are described in this paper, along with their similarities and differences. Through our extensive review, it was discovered that there are five key elements to a reliable integrated rapid manufacturing system: process planning software, motion system, control system, unit manufacturing process, and a finishing process. By studying the manner in which all other systems have been integrated, a table of successful integrated manufacturing system element combinations has been complied, documenting each of the key element choices, resulting in a variety of modular designs. This paper further discusses the importance of the five elements in manufacturing system integration, and how an integrated system is the way to move forward in the manufacturing domain. To that end, a rapid manufacturing system design methodology was developed that explores designs via process analysis to discover integration potential. Cost-benefit analysis is then used to assess the performance of the new system. This analysis determines if all needs have been met, while staying within the constraints of time and resources. Additionally, a table of common issues and obstacles encountered during manufacturing system development has been compiled to assist in the design and development of future rapid manufacturing systems. To illustrate the design methodology, our modular design experience with a laser aided manufacturing process is presented. Unit manufacturing process integration has increased the productivity and capabilities of our system, which reduced resource volume and increased productivity.

Determination of Influencing Factors on Interface Strength of Additively Manufactured Multi-Material Parts by Material Extrusion

“…[3,4,6,13] Since MMAM offers a multitude of new design potentials, designers need to be aided in their decision-making regarding material choice, machine operation and part design. [14][15][16][17] Hence, this publication aims to give recommendations for this decision making process.…”

Laser Additive Manufacturing of Novel Aluminum Based Nanocomposite Parts: Tailored Forming of Multiple Materials

“…Therefore, the exploration of advanced processing techniques which are capable of production of nanocomposites with tailored microstructure is receiving considerable research interest. SLM, as a typical AM/3D printing (3DP) technique [19][20][21][22][23][24][25], enables rapid fabrication of three-dimensional parts with any complex shapes directly from loose powders [26][27][28][29][30][31]. During SLM process, a high-energy laser beam is used to selectively fusing a thin layer of powder which then consolidates to form a solid layer.…”

Hybrid Manufacturing System Design and Development

“…The documented information in Table 2 does not address every possible integration obstacle, but is meant to be comprehensive from what is found in the literature and personal experience. Issues outside of integration, such as material properties can be found in (Nagel & Liou, 2010).…”

“…Moreover, the process can be controlled and monitored from a remote location, increasing the safety of the manufacturing process. The hybrid manufacturing system architecture follows the modular, integration element structure as defined in (Nagel & Liou, 2010). Figure 2 shows the direct mapping of customer needs and requirements to the overall system architecture as well as the dependency relationships.…”

“…This section reviews the qualitative and quantitative modeling efforts of material and information as well as the system architecture design that incorporates the knowledge gained through modeling. Cost modeling for the hybrid system has only been temporal, however, a cost benefit analysis as proposed in (Nagel & Liou, 2010) could be performed to quantify the savings.…”