Hybrid Manufacturing Process Greatly Reduces Production Costs of CNC Machined Plastic Parts

2020 ◽  
Author(s):  
James William Hebel
Keyword(s):  
Manufacturing Process ◽  
Production Costs ◽  
Hybrid Manufacturing ◽  
Plastic Parts

Hybrid Manufacturing System Modeling and Development

2012 ◽  
Author(s):  
Jacquelyn K. S. Nagel ◽  
Frank W. Liou
Keyword(s):  
Hybrid System ◽  
Manufacturing Process ◽  
Manufacturing Systems ◽  
Manufacturing System ◽  
System Modeling ◽  
Production Costs ◽  
Production Model ◽  
Hybrid Manufacturing ◽  
Lamp System ◽  
Metallic Parts

Reliable and economical fabrication of metallic parts with complicated geometries is of considerable interest for the aerospace, medical, automotive, tooling and consumer products industries. In an effort to shorten the time-to-market, decrease the manufacturing process chain, and cut production costs of products produced by these industries, research has focused on the integration of multiple unit manufacturing processes into one machine. The end goal is to reduce production space, time, and manpower requirements. Our research into hybrid manufacturing systems has lead to the integration of additive and subtractive processes within a single machine footprint such that both processes are leveraged during fabrication. The laser aided manufacturing process (LAMP) system provides a rapid prototyping and rapid manufacturing infrastructure for research and education. The LAMP system creates fully dense, metallic parts and provides all the advantages of commercial laser metal deposition (LMD) systems. This hybrid system is a very competitive and economical approach to fabricating metallic structures. Hybrid manufacturing systems facilitate a sustainable and intelligent production model and offer flexibility of infrastructure to adapt with emergent technology, customization, and changing market needs. This paper summarizes the salient research activities and the findings of those activities related to the modeling and development of the hybrid manufacturing system. Our qualitative and quantitative modeling efforts, as well as the resultant system architecture are described. The approach and strategies utilized in this research coalesce to facilitate an interdisciplinary approach to the development a hybrid manufacturing system to produce metal parts that are not only functional but also processed to the final desired surface-finished and tolerance. Furthermore, the approach to hybrid system modeling and development can assist in general with integrated manufacturing systems.

Integrating Product Design With Manufacturing Process Design Using the Robust Concept Exploration Method

1996 ◽  
Author(s):  
Jesse D. Peplinski ◽  
Janet K. Allen ◽  
Farrokh Mistree
Keyword(s):  
Product Design ◽  
Process Design ◽  
Manufacturing Process ◽  
Response Surfaces ◽  
Production Costs ◽  
Early Stages ◽  
Trade Offs ◽  
Development Costs ◽  
Concept Exploration ◽  
Product And Process

Abstract How can the manufacturability of different product design alternatives be evaluated efficiently during the early stages of concept exploration? The benefits of such integrated product and manufacturing process design are widely recognized and include faster time to market, reduced development costs and production costs, and increased product quality. To reap these benefits fully, however, one must examine product/process trade-offs and cost/schedule/performance trade-offs in the early stages of design. Evaluating production cost and lead time requires detailed simulation or other analysis packages which 1) would be computationally expensive to run for every alternative, and 2) require detailed information that may or may not be available in these early design stages. Our approach is to generate response surfaces that serve as approximations to the analyses packages and use these approximations to identify robust regions of the design space for further exploration. In this paper we present a method for robust product and process exploration and illustrate this method using a simplified example of a machining center processing a single component. We close by discussing the implications of this work for manufacturing outsourcing, designing robust supplier chains, and ultimately designing the manufacturing enterprise itself.

Mold Flow-Based Mold Flow Analysis of Copier Parts and its Solution Optimization

2012 ◽  
Vol 538-541 ◽  
pp. 1072-1075
Author(s):  
Jun Kai Yang ◽  
Yun Jie Xu
Keyword(s):  
Product Quality ◽  
Design Process ◽  
Flow Analysis ◽  
Production Costs ◽  
Improve Product Quality ◽  
Cooling Process ◽  
Mold Flow Analysis ◽  
Product Design Process ◽  
Plastic Parts ◽  
Mold Flow

Mold flow software is used to conduct mold flow analysis of copier parts, simulate its filling and cooling process, and predict possible defects in the product design process in order to determine the formability of plastic parts and product quality. The optimal mold structure can be obtained by comparing different solutions so as to save production costs and improve product quality and efficiency.

Investigation of machining coolant residue cleaning methods for Ti6Al4V part fabrication through hybrid manufacturing process

2018 ◽  
Vol 16 ◽  
pp. 10-13 ◽  
Author(s):  
Lei Yan ◽  
Yunlu Zhang ◽  
Joseph W. Newkirk ◽  
Frank Liou ◽  
Eric Thomas ◽  
...  
Keyword(s):  
Manufacturing Process ◽  
Hybrid Manufacturing ◽  
Cleaning Methods

Virtual Assembly Production Analysis of Composite Aircraft Structures

1995 ◽  
Author(s):  
David E. Lee ◽  
H. Thomas Hahn
Keyword(s):  
Manufacturing Process ◽  
Context Effects ◽  
Virtual Assembly ◽  
Virtual Manufacturing ◽  
Production Costs ◽  
Process Conditions ◽  
Aircraft Structures ◽  
Production Analysis ◽  
The Impact ◽  
Assembly Production

Abstract Concurrent with the use of tailored materials for specific applications has been the understanding that a product’s design has a significant and measurable effect on manufacturing process cycle times and unit production costs. In order to reliably manufacture and assemble aircraft structures fabricated from composite materials on a cost-effective basis, an environment for virtual assembly production analysis is being developed. Within this environment, members of an aircraft’s integrated product development team can rapidly assess the impact of design decisions on individual assembly operations and overall aircraft assembly in a virtual manufacturing context. Effects related to joint design and component matings are measured based on force and process conditions as well as the types of tooling required for final assembly. By evaluating assembly production impacts early during product design, the costly design-manufacture-redesign cycle is redefined and recast based on the realities of manufacturing process constraints.

Build Strategy Investigation of Ti-6Al-4V Produced Via a Hybrid Manufacturing Process

JOM ◽  
2018 ◽  
Vol 70 (9) ◽  
pp. 1706-1713 ◽  
Author(s):  
Lei Yan ◽  
Wenyuan Cui ◽  
Joseph W. Newkirk ◽  
Frank Liou ◽  
Eric E. Thomas ◽  
...  
Keyword(s):  
Manufacturing Process ◽  
Hybrid Manufacturing

Produktivitätssteigerung durch Hybridisierung im 3D-Druck/Process development for the automated production of plastic parts with integrated functional components. Increased productivity through hybridization in 3D printing

2020 ◽  
Vol 110 (07-08) ◽  
pp. 521-525
Author(s):  
Michael Baranowski ◽  
Markus Netzer ◽  
Sven Coutandin ◽  
Jürgen Fleischer
Keyword(s):  
Additive Manufacturing ◽  
3D Printing ◽  
Manufacturing Process ◽  
Process Development ◽  
Flexible Production ◽  
Additive Fertigung ◽  
Automated Production ◽  
Individualized Production ◽  
Plastic Parts ◽  
Functional Components

Die additive Fertigung erlaubt eine standortunabhängige sowie de facto individualisierte Produktion von Bauteilen mit nahezu beliebiger Komplexität. Für die flexible Herstellung von hochfunktionalen Hybridbauteilen fehlt es allerdings an entsprechenden Maschinenkonzepten sowie Automatisierungslösungen. Durch ein hier vorgestelltes Anlagenkonzept sollen Funktionskomponenten in den additiven Herstellungsprozess integriert und neue Möglichkeiten der Bauteilhybridisierung erforscht werden.   Additive manufacturing allows a location-independent and de facto individualized production of components of almost any complexity. However, there is a need for appropriate machine concepts and automation solutions for the flexible production of highly functional hybrid components. A plant concept presented here is intended to integrate functional components into the additive manufacturing process and to explore new possibilities for component hybridization.

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