chap1

• Manufacturing involves two main processes: design and manufacturing
• Design process sub-processes:

  • Synthesis
  • Analysis
• Design phase requires CAD tools and involves geometric modeling techniques, graphics aids, manipulations, and visualization
• Manufacturing phase requires CAM tools and involves process planning, CAPP techniques, cost analysis, material and tooling specification
• Digital modeling and manufacturing/fabrication combine 3D modeling or CAD with additive and subtractive manufacturing
• Digital manufacturing is a production method where computer technology creates products with little to no human involvement
• Three main types/areas of digital manufacturing:

  1. Product life cycle

  2. Smart factory

  3. Value chain management
• Benefits of digital manufacturing:

  • Increased efficiency
  • Faster innovation
  • Customer satisfaction
  • Cost reduction
• Classification of similar technologies used in Digital Manufacturing:

  • CNC Router
  • CNC Mills
  • CNC Plotters
  • CNC Embroiderer
  • Laser Cutter
  • Water Jet Cutter
  • 3D Printer/Additive Manufacturing System
• Desktop Manufacturing:

  • Ability to manufacture physical items from your desktop
  • Includes small-scale manufacturing and the ability to work and produce from home or neighborhood
• Direct digital manufacturing (DDM) uses additive manufacturing technologies for production of end-use components
• Direct Digital Manufacturing (DDM) is also known as "Rapid Manufacturing"
• DDM is not a replacement for mass production applications, as customized geometry cannot be mass-produced using traditional manufacturing technologies
• DDM applications have taken advantage of the geometric complexity capabilities of Additive Manufacturing (AM) technologies to produce parts with customized geometries
• Additive manufacturing is one of the core group of digital manufacturing solutions that include Artificial Intelligence, the Internet of Things, and Robotics
• The 4th industrial revolution is the analogue-to-digital shift that has already transformed the global manufacturing industry, fundamentally changing the way products are conceived, designed, produced, distributed, and consumed
• 3D printing/Additive Manufacturing (3DP/AM) is enabling physical output from entirely digital information, advancing rapid prototyping and rapid tooling
• 3DP/AM has moved away from just being a tool for prototyping and design, with the development of powerful industrial 3D printers that deliver quality, functional final parts, and new levels of productivity
• 3D printing is placing power in the hands of smaller and individual creators, allowing consumers to design and create their own unique products and solutions
• • No Hard Tooling: no need to design, fabricate, and inventory tools; economical low-volume production
• Unique capabilities of AM technologies that lead to DDM applications are driven by factors such as:

  • Unique Shapes: parts with customized shapes
  • Complex Shapes: improved performance
  • Lot Size of One: economical to fabricate customized parts
  • Fast Turnaround: save time and costs; increase customer satisfaction
  • Digital Manufacturing: precisely duplicate CAD model
  • Digital Record: have reusable dataset
  • Electronic "Spare Parts": fabricate spare parts on demand, rather than holding inventory
• The capability to create customized, unique geometries is an important factor for DDM
• The capability of building parts with complex geometries is another benefit of DDM
• Economical lot sizes of one are another important DDM capability, as no tooling is required and time and costs are often significantly reduced
• Digital manufacturing enables digital archiving of the design and manufacturing information associated with the part, impacting global enterprises significantly
• A digital record allows for the archiving of design information associated with a part, streamlining record keeping, sharing of records, and fabricating replacement parts
• The advantages of not requiring tooling for part fabrication are numerous and significant, making DDM economically competitive across many applications for small lot size production
• Direct digital manufacturing is becoming more widely adopted due to its ability to produce manufactured parts more quickly and cost-effectively compared to traditional manufacturing methods such as injection molding