Acquiring Manufacturing Processes Knowledge for Design

SUMMARY Much of the work done in concurrent design assumes that manufacturing process knowledge has been codified and that manufacturing process models exist. However, for new solid free-form manufacturing processes, such as the shape deposition process being developed at Carnegie Mellon, these assumptions are not valid. In the shape deposition fabrication process, a part is built by successively depositing materials in thin layers. Each layer can contain several materials and creating each layer requires several manufacturing subprocesses which include micro-casting, thermal spraying, shot peening and machining. Some of these manufacturing subprocesses are only partially understood; their use in combination to form a single multi-material layer is not well understood; and the process of creating a mechanical part or assembly from thin multi-material layers is also not well understood. One of the salient features of shape deposition, as well as most solid free-form manufacturing processes, is that it requ...

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