Rapid Manufacturing

An Industrial Revolution for the Digital Age
1. Auflage 2006
ISBN: 978-0-470-01613-8
Verlag: Wiley

Buch, Englisch, 304 Seiten, Format (B × H): 174 mm x 252 mm, Gewicht: 713 g

Rapid Manufacturing is a new area of manufacturing developed from a family of technologies known as Rapid Prototyping. These processes have already had the effect of both improving products and reducing their development time; this in turn resulted in the development of the technology of Rapid Tooling, which implemented Rapid Prototyping techniques to improve its own processes. Rapid Manufacturing has developed as the next stage, in which the need for tooling is eliminated. It has been shown that it is economically feasible to use existing commercial Rapid Prototyping systems to manufacture series parts in quantities of up to 20,000 and customised parts in quantities of hundreds of thousands. This form of manufacturing can be incredibly cost-effective and the process is far more flexible than conventional manufacturing.

Rapid Manufacturing: An Industrial Revolution for the Digital Age addresses the academic fundamentals of Rapid Manufacturing as well as focussing on case studies and applications across a wide range of industry sectors. As a technology that allows manufacturers to create products without tools, it enables previously impossible geometries to be made. This book is abundant with images depicting the fantastic array of products that are now being commercially manufactured using these technologies.
- Includes contributions from leading researchers working at the forefront of industry.
- Features detailed illustrations throughout.

Rapid Manufacturing: An Industrial Revolution for the Digital Age is a groundbreaking text that provides excellent coverage of this fast emerging industry. It will interest manufacturing industry practitioners in research and development, product design and materials science, as well as having a theoretical appeal to researchers and post-graduate students in manufacturing engineering, product design, CAD/CAM and CIFM.

Autoren/Hrsg.

Hopkinson, Neil

Hague, Richard

Dickens, Philip

Fachgebiete

• Technische Wissenschaften Maschinenbau | Werkstoffkunde Produktionstechnik Computergestützte Fertigung

Inhaltsverzeichnis

List of Contributors xiii
Editors xv

Foreword xvii
Terry Wohlers

1 Introduction to Rapid Manufacturing 1
Neil Hopkinson, Richard Hague and Phill Dickens

1.1 Definition of Rapid Manufacturing 1
1.2 Latitude of Applications 2
1.3 Design Freedom 2
1.4 Economic for Volumes down to One 3
1.5 Overcoming the Legacy of Rapid Prototyping 3
1.6 A Disruptive Technology 4
1.7 A Breakdown of the Field of Rapid Manufacturing 4

2 Unlocking the Design Potential of Rapid Manufacturing 5
Richard Hague

2.1 Introduction 5
2.2 Potential of Rapid Manufacturing on Design 7
2.3 Geometrical Freedom 9
2.4 Material Combinations 16
2.5 Summary 17

3 Customer Input and Customisation 19
R.I. Campbell

3.1 Introduction 19
3.2 Why Is Customer Input Needed? 20
3.3 What Input can the Customer Make? 21
3.4 How Can Customer Input Be Captured? 23
3.5 Using Customer Input within the Design Process 26
3.6 What Is Customisation? 28
3.7 Determining Which Features to Customise 29
3.8 Additional Customisation Issues 30
3.9 Case Study – Customising Garden Fork Handles 31
3.10 Conclusions 35

4 CAD and Rapid Manufacturing 39
Rik Knoppers and Richard Hague

4.1 Introduction 39
4.2 CAD Background 40
4.3 Relations between CAD and Rapid Manufacturing 43
4.4 Future Developments Serving Rapid Manufacturing 43
4.5 CAD for Functionally Graded Materials (FGMs) 48
4.6 Conclusion 54

5 Emerging Rapid Manufacturing Processes 55
Neil Hopkinson and Phill Dickens

5.1 Introduction 55
5.2 Liquid-Based Processes 58
5.3 Powder-Based Processes 64
5.4 Solid-Based Processes 75

6 Materials Issues in Rapid Manufacturing 81
David L. Bourell

6.1 Role of Materials in Rapid Manufacturing 81
6.2 Viscous Flow 81
6.3 Photopolymerization 83
6.4 Sintering 84
6.5 Infiltration 91
6.6 Mechanical Properties of RM Parts 94
6.7 Materials for RM Processes 97
6.8 The Future of Materials in Rapid Manufacturing 98

7 Functionally Graded Materials 103
Poonjolai Erasenthiran and Valter Beal

7.1 Introduction 103
7.2 Processing Technologies 104
7.3 Rapid Manufacturing of FGM Parts – Laser Fusion 106
7.4 Modelling and Software Issues 111
7.5 Characterisation of Properties 113
7.6 Deposition Systems 117
7.7 Applications 119

8 Materials and Process Control for Rapid Manufacture 125
Tim Gornet

8.1 Introduction 125
8.2 Stereolithography 126
8.4 Fused Deposition Modeling 138
8.5 Metal-Based Processes 142

9 Production Economics of Rapid Manufacture 147
Neil Hopkinson

9.1 Introduction 147
9.2 Machine Costs 148
9.3 Material Costs 149
9.4 Labour Costs 150
9.5 Comparing the Costs of Rapid Manufacture with Injection Moulding 152

10 Management and Implementation of Rapid Manufacturing 159
Chris Tuck and Richard Hague

10.1 Introduction 159
10.2 Costs of Manufacture 160
10.3 Overhead Allocation 160
10.4 Business Costs 160
10.5 Stock and Work in Progress 161
10.6 Location and Distribution 162
10.7 Supply Chain Management 164
10.8 Change 170
10.9 Conclusions 171

11 Medical Applications 175
Russ Harris and Monica Savalani

11.1 Introduction 175
11.2 Pre-Surgery RM 176
11.3 Orthodontics 179
11.4 Drug Delivery Devices 181
11.5 Limb Prosthesis 183
11.6 Specific Advances in Computer Aided Design (CAD) 184
11.7 In Vivo Devices 185

12 Rapid Manufacturing in the Hearing Industry 195
Martin Masters, Therese Velde and Fred McBagonluri

12.1 The Hearing Industry 195
12.2 Manual Manufacturing 196
12.3 Digital Manufacturing 197
12.4 Scanning 198
12.5 Electronic Detailing 199
12.6 Electronic Modeling 200
12.7 Fabrication 202
12.8 Equipment 203
12.9 Selective Laser Sintering (SLS) 203
12.10 Stereolithography Apparatus (SLA) 204
12.11 Raster-Based Manufacturing 206
12.12 Materials 207
12.13 Conclusion 208

13 Automotive Applications 211
Graham Tromans

13.1 Introduction 211
13.2 Formula 1 212
13.3 Cooling Duct 213
13.4 The 'Flickscab' 213
13.5 NASCAR 215
13.6 Formula Student 215

14 Rapid Manufacture in the Aeronautical Industry 221
Brad Fox

14.1 Opportunity 221
14.2 Overview 221
14.3 Historical Perspective 222
14.4 Aeronautical Requirements for RM 223
14.5 Why RM Is Uniquely Suited to the Aeronautical Field 223
14.6 Acceptable Technologies 225
14.7 Qualifying RM Systems 228
14.8 Summary 231
14.9 Case Studies 231

15 Aeronautical Case Studies using Rapid Manufacture 233
John Wooten

15.1 Introduction 233
15.2 Problem and Proposed Solution 233
15.3 Benefits of a Rapid Manufacture Solution 235
15.4 Pre-Production Program 237
15.5 Production 238
15.6 Summary 239

16 Space Applications 241
Roger Spielman

16.1 Introduction 241
16.2 Building the Team 242
16.3 Quality Assurance 244
16.4 How to 'Qualify' a Part Created Using This Process 245
16.5 Producing Hardware 246

17 Additive Manufacturing Technologies for the Construction Industry 249
Rupert Soar

17.1 Introduction 249
17.2 The Emergence of Freeform Construction 250
17.3 Freeform Construction Processes: A Matter of Scale 262
17.4 Conclusions 271

18 Rapid Manufacture for the Retail Industry 275
Janne Kyttanen

18.1 Introduction 275
18.2 Fascinating Technology with Little Consumer Knowledge 275
18.3 The Need for Rapid Prototyping to Change to Rapid Manufacturing 276
18.4 Rapid Manufacturing Retail Applications 276
18.5 Mass Customisation 280
18.6 Experimentation and Future Applications 282

Index 283

Über Autor(innen)

Neil Hopkinson is a lecturer in the Wolfson School of Mechanical and Manufacturing Engineering at Loughborough University, UK. Having obtained his PhD in Rapid Tooling in 1999, Neil began to look into the economic viability of Rapid Manufacturing. Inspired by the findings of this research Neil began to investigate lowcost, high-speed Rapid Manufacturing processes while also focusing his research on material properties in powder-based layer manufacturing processes. To date Neil has secured over £1 million of research funding and published over 40 journal/conference papers; he was also an invited visiting lecturer at the University of Queensland in Australia.

Phill Dickens is Professor of Manufacturing Technology and Director of the Innovative Manufacturing and Construction Research Centre at Loughborough University, UK. He is also Associate Dean of Research for the Engineering Faculty. Phill started work in the area of Rapid Prototyping in 1990, working on processes such as 3D Welding and using copper coated SL models as electrodes for EDM. The research work has changed emphasis since then from Rapid Prototyping to Rapid Tooling and is now concentrating on Rapid Manufacturing.

Richard Hague is a Senior Lecturer and Head of the Rapid Manufacturing Research Group at Loughborough University, UK. He has been involved with Rapid Prototyping and Rapid Manufacturing (RM) research since 1993, and is now Principal Investigator on several large EPSRC, DTI and EU funded research projects. He was also instrumental in setting up and managing the successful Rapid Manufacturing Consortium that now operates from Loughborough. Richard has many academic publications in the area of Rapid Manufacturing and is referee to several international academic journals and conferences. He also holds a patent that was gained as part of his PhD studies which is licensed to the predominant manufacturer of Rapid Prototyping equipment (3D Systems Inc.).