Design for Manufacturing and Additive Manufacturing Techniques

These flashcards cover key concepts, processes, and definitions related to manufacturing design and additive manufacturing techniques.

Additive Manufacturing

Commonly referred to as 3D printing, it involves producing a prototype quickly by building up a 3D object in layers.

Advantages of Additive Manufacturing

Includes no tooling costs, minimal setup time, quick lead times, valuable feedback for development, and the ability to create complex profiles.

Disadvantages of Additive Manufacturing

Includes the inability to always simulate true material performance, increasing cost per part with higher quantities, and the requirement of a 3D model.

3D Printing

A process of additive manufacturing where components are sliced into layers and built up layer by layer.

4D Printing

An extension of 3D printing that incorporates smart materials capable of changing shape in response to changes in environmental conditions.

5D Printing

An advanced form of 3D printing that allows for extra axes of movement, increasing part complexity while reducing or eliminating supports.

FDM (Fused Deposition Method)

A 3D printing method that builds models using an extruder that deposits uniform liquid materials that solidify.

Key Characteristics of FDM

Known for quick processing, weak perpendicular strength, and requiring supports during printing.

Popular Materials for FDM

Commonly used materials include ABS, PLA, PET-G, and TPE.

SLA (Stereolithography Apparatus)

A 3D printing method that creates layers by curing thermosetting resin with a laser.

Materials Used in SLA Printing

Primarily thermosetting resins that can simulate various plastics, elastomers, and ceramics.

LOM (Laminated Object Manufacturing)

A process that builds models from thin sheets of material, such as paper or plastic.

Key Characteristics of LOM

Offers excellent surface finish and comparable strength to molded parts but is slow and requires processing post-printing.

SLS (Selective Laser Sintering)

A 3D printing process that uses powdered materials fused by a laser.

Advantages of SLS

Provides excellent strength and surface finish, though supports are needed and certain materials require post-processing.

Subtractive Manufacturing Processes

Methods that start with material removal processes like cutting, milling, or grinding to achieve the desired shape.

Turning in Subtractive Manufacturing

A process where round material is rotated and material is cut away by a tool.

Key Characteristics of Turning

Low lead time and suitability for batch production due to wastage.

Abrading Process

A manufacturing technique involving rubbing a softer material with a harder one to shape parts.

Water-Jet Cutting

A cutting technique that uses high-pressure water to slice materials, typically for flat sheets.

Laser-Cutting

A method where a laser vaporizes material to cut precise shapes quickly with minimal setup.

Milling/Routing

Manufacturing processes performed by machines or by hand to cut and shape materials.

Vacuum Forming

A process where a heated thermoplastic sheet is molded into a shape using a vacuum.

Characteristics of Vacuum Forming

Offers low cost and high production volume but has limited potential for complex shapes.

Injection Moulding

A process where molten plastic is injected into a die at high pressure to form parts.

Characteristics of Injection Moulding

Allows for small intricate parts and high-speed production but has high setup costs.

Blow Moulding

A manufacturing technique used to create hollow plastic containers by expanding a heated blank.

Rotational Moulding

A method for producing parts by heating plastic powder in a rotating mould.

Extrusion Moulding

A process where molten thermoplastic is forced through a die to create continuous profiles.

Compression Moulding

A technique for shaping thermoset plastics using heat and pressure in a mould.

Cold Forging Process

Involves plastically deforming sheet metal parts with considerable force.

Key Characteristics of Cold Forging

Low tooling costs and well-suited for 3D parts but limited in shapes.

Characteristics of Adhesives

Used for joining materials; properties vary greatly among different kinds.

Fusing Techniques

Involves heating parts to be joined, such as welding and brazing, to create a solid joint.

Nails and Pins

Temporary joining methods that work well with wood to create friction and compression holds.

Rivets

A permanent joining technique that requires pre-drilled holes in both materials.

Bolts

Fasteners that provide strong joins by passing through pre-drilled holes.

Screws

Offer a reliable, removable joining method by cutting into the material's surface.

Craft Production

A manual and skill-oriented production system for small quantities of parts.

Assembly Line Production

A production method where components are assembled in a sequence along a conveyor.

Automated Production

A system where machines operate autonomously, performing the bulk of production tasks.

Mechanised Production

Involves human control over machines, often relying on skills to produce parts.

Benefits of CIM

Improves integration and efficiency in production processes, accounting, and inventory.

One-Off Production

Manufacturing highly specialized items made to order, typically at a small scale.

Batch Production

Production of a set quantity of products requiring medium-skilled labor.

Mass Production

A system for producing high quantities at lower costs, with an emphasis on automation.

Continuous Flow Production

An ongoing manufacturing process that runs without stops, producing parts continuously.

Mass Customisation

Combines mass production techniques with custom options for individual orders.

Design for Processes

A strategy to minimize the energy, waste, or steps needed to produce a product.

Design for Assembly

Focuses on simplifying assembly to reduce cost, labor, and time.

Design for Disassembly

Designing products to ease the disassembly process for maintenance and recycling purposes.

Design for Materials

The process of selecting materials that reduce toxicity and total material usage.

Characteristics of Robots

Robot capabilities include work envelope, load capacity, and performance efficiency.

Single Task Robots

Designed to perform one specific task with high precision.

Multi-Task Robots

Robots capable of multiple tasks through pre-programmed schedules or sensors.

First Generation Robots

Basic robots that make precise movements but lack sensors and require constant monitoring.

Third Generation Robots

Autonomous robots operating with minimal human intervention, often equipped with AI.

Advantages of Robotic Systems

Includes increased production rates, lower costs, and improved precision.

Disadvantages of Robotic Systems

Initial high costs, need for programming expertise, and potential job losses.