Manufacturing Processes For Design Professionals Pdf Free Download
Brandi Baylon
Over the past 20 years Rob has worked as a designer on projects ranging from multidisciplinary academic research through to creating new products and materials. His research about the opportunities of materials and manufacturing for designers has given him unprecedented insight into the inner workings of some of the most innovative factories and ground-breaking research from around the world.
I'm fresh out of school and working for a small aerospace mfg company. We are in the process of designing tools for composite lay-up parts. We were given models by the customer to work off of but some features are intricate and almost seem impossible to manufacture, in my opinion. I was curious to know if someone is just spitting out CAD designs without considering the manufacturing process? Since these models are MBD, we were not given a 2D drawing.
Manufacturing Processes For Design Professionals Pdf Free Download
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Manufacturing Engineering Technology is the profession in which an understanding and application of a broad range of technologies is necessary for production and control of manufacturing processes. Manufacturing includes methods of production of industrial commodities and consumer products. The manufacturing professional must be able to plan, design, and implement sequence of operations using current technologies to produce products at competitive prices. Four-year B.S. degree graduates qualify for jobs related to production, productivity improvement, and process design. They also qualify for supervisory and managerial positions in plant engineering.
Design for Manufacturing (DFM) is the process of designing parts, components or products for ease of manufacturing with an end goal of making a better product at a lower cost. This is done by simplifying, optimizing and refining the product design. The acronym DFMA (Design for Manufacturing and Assembly) is sometimes used interchangeably with DFM.
In determining the manufacturing process, Jeff said the DFM took into consideration the quantity of parts being made, the material being used, the complexity of the surfaces, the tolerances required and whether there were secondary processes required. You'll note that many of the same questions he asks with regard to process will also come up under the 'Design' heading.
The goal of DFM is to reduce manufacturing costs without reducing performance. In addition to the principles of DFM, here are five factors that can affect design for manufacturing and design for assembly:
The more complex the process of making your product, is the more variables for error are introduced. Remember what Jeff said: All processes have limitations and capabilities. Only include those operations that are essential to the function of the design.
The book Computer-Aided Manufacturing offers 10 generally accepted Design for Manufacturing principles that were developed to help designers decrease the cost of and complexity of manufacturing a product. The results of a successful DFM are quantifiable in a host of ways.
A variety of plastic manufacturing processes have been developed to cover a wide range of applications, part geometries, and types of plastics. For any designer and engineer working in product development, it is critical to be familiar with the manufacturing options available today and the new developments that signal how parts will be made tomorrow.
Form: Do your parts have complex internal features or tight tolerance requirements? Depending on the geometry of a design, manufacturing options may be limited, or they may require significant design for manufacturing (DFM) optimization to make them economical to produce.
Material: What stresses and strains will your product need to stand up to? The optimal material for a given application is determined by a number of factors. Cost must be balanced against functional and aesthetic requirements. Consider the ideal characteristics for your specific application and contrast them with the available choices in a given manufacturing processes.
Thermoplastics are the most commonly used type of plastic. The main feature that sets them apart from thermosets is their ability to go through numerous melt and solidification cycles without significant degradation. Thermoplastics are usually supplied in the form of small pellets or sheets that are heated and formed into the desired shape using various manufacturing processes. The process is completely reversible, as no chemical bonding takes place, which makes recycling or melting and reusing thermoplastics feasible.
While most plastic manufacturing processes require expensive industrial machinery, dedicated facilities, and skilled operators, 3D printing allows companies to easily create plastic parts and rapid prototypes in-house.
Unlike most other plastic manufacturing processes, CNC machining is a subtractive process where material is removed by either a spinning tool and fixed part (milling) or a spinning part with a fixed tool (lathe).
Injection molding can be used to produce highly complex parts, but certain geometries will increase cost significantly. Following design for manufacturing (DFM) guidelines will help to keep tooling costs manageable. Creating new molds for injection molding can take months to complete, and their costs can run into five or six digits.
Despite the high initial costs and slow ramp up, injection molding has no match for high volume applications. Once the tooling is up and running, cycle times only take a few seconds, and millions of high-quality parts can be produced at a fraction of the cost of all other manufacturing processes.
Plastic manufacturing processes are constantly evolving and the inflection points where it makes sense to move from one technique to another are shifting due to improvements in equipment, materials, and economies of scale.
The undergraduate Mechanical Engineering Technology (MET) program is designed with an applications-oriented structure. Many of the technical science courses have an accompanying laboratory component providing hands-on activities. Coursework emphasizes mechanical design, thermal systems design, manufacturing processes design and implementation, measurement, data collection and analysis, documentation, and written/oral report preparation/presentation.
The program aims to develop core competencies in engineering fundamentals (statics, strengths of materials, materials science, fluid dynamics, and electrical circuits), manufacturing applications (manufacturing processes, machining, welding and joining processes, design for manufacturing and tooling, quality assurance, etc.), mechanical design (computer-aided design, mechanisms, machine design, fluid power technology, measurement and test, etc.), and thermal sciences (thermodynamics, heat transfer, and heating, ventilation, and air conditioning, etc.). Extensive course work in the physical sciences and mathematics is included.
Mechanical Engineering Technology is concerned with the application of scientific and engineering knowledge in support of engineering activities. Specifically, the mechanical engineering technology professional provides the engineering services required to support the transformation of the results of scientific endeavors into useful products and services. Students who choose a career in mechanical engineering technology may pursue any number of career paths including, but not limited to: machine and product design engineering, product and system evaluation, research laboratory experimental support, prototype evaluation, plant operation and management, quality assurance, technical sales, manufacturing methods improvement, building energy systems design, control and installation, project management, energy systems support, alternative energy development and systems sustainability.
The mechanical engineering technology graduate is equipped to perform analysis and planning steps to convert ideas into finished products, in the most efficient and safe manner. They may be the engineering professional who develops designs and design-build instructions using various computer programs, develops efficient manufacturing processes and manages the operation of manufacturing equipment, handles inspections, analyzes and resolves production problems, and manages the implementation of product realization and product improvement activities.
Simufact software solutions cover a huge number of manufacturing processes in the metal working industry. We have bundled these processes in three groups (Forming, Joining, and Additive Manufacturing) and assigned them to currently 17 fields of application which in turn contain various special processes. Find out which typical tasks appear during process design and optimization and how the user can be supported in completing this tasks by simulation.
3D printing allows for the design and print of more complex designs than traditional manufacturing processes. More traditional processes have design restrictions which no longer apply with the use of 3D printing.
Often the design and fabrication processes of PCB manufacturing have different entities behind them. In many cases, the contract manufacturer (CM) may fabricate a printed circuit board based on the design created by the original equipment manufacturer (OEM). Collaboration on components, design considerations, file formats and board materials between these groups will ensure an effective process and seamless transition between phases.
The designer should consult with the fabricator on available components. Ideally, the fabricator will have all components required by the design on hand. If something is missing, the designer and fabricator will need to find a compromise to ensure faster manufacturing while still meeting minimum design specifications.
Although technology has taken over many aspects of our lives, our product design and manufacturing processes are still largely stuck in the industrial age. Companies struggle to efficiently create better-performing products and keep costs low. After extensive experimentation, they arrive at the best designs they can. Then, they feed instructions into manufacturing machines, which churn out thousands of identical products or parts, leaving little room for customization.
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