Details for: Rapid manufacturing : an industrial revolution for the digital age /

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Rapid manufacturing : an industrial revolution for the digital age / editors, N. Hopkinson, R.J.M. Hague and P.M. Dickens.

Contributor(s): Hopkinson, N

| Hague, R. J. M

| Dickens, P. M

Publisher: Chichester : John Wiley, 2006Description: xviii, 285 p. ill.; 25 cm001: 13745ISBN: 0470016132; 9780470016138Subject(s): Rapid prototyping | Rapid tooling | Computer integrated manufacturing systems | CAD/CAM systemsDDC classification: 670.285 LOC classification: TS171.4 | .R37 2006

Holdings
Item type	Current library	Collection	Call number	Copy number	Status	Date due	Barcode
Book	MAIN LIBRARY Book	PRINT	670.285 RAP (Browse shelf(Opens below))	1	Available		088940

Enhanced descriptions from Syndetics:

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.

Includes bibliographies and index.

Table of contents provided by Syndetics

List of Contributors (p. xiii)
Editors (p. xv)
Foreword (p. xvii)
1 Introduction to Rapid Manufacturing (p. 1)
1.1 Definition of Rapid Manufacturing (p. 1)
1.2 Latitude of Applications (p. 2)
1.3 Design Freedom (p. 2)
1.4 Economic for Volumes down to One (p. 3)
1.5 Overcoming the Legacy of Rapid Prototyping (p. 3)
1.6 A Disruptive Technology (p. 4)
1.7 A Breakdown of the Field of Rapid Manufacturing (p. 4)
2 Unlocking the Design Potential of Rapid Manufacturing (p. 5)
2.1 Introduction (p. 5)
2.2 Potential of Rapid Manufacturing on Design (p. 7)
2.2.1 Conventional 'Design for Manufacture' (DFM) (p. 7)
2.2.2 Conventional Design for Assembly (DFA) (p. 8)
2.2.3 Impact of RM on DFM and DFA (p. 8)
2.3 Geometrical Freedom (p. 9)
2.3.1 Design Complexity/Optimisation (p. 10)
2.3.2 Part Consolidation (p. 11)
2.3.3 Body Fitting Customisation (p. 12)
2.3.4 Multiple Assemblies: Textiles (p. 13)
2.4 Material Combinations (p. 16)
2.5 Summary (p. 17)
References (p. 18)
3 Customer Input and Customisation (p. 19)
3.1 Introduction (p. 19)
3.2 Why Is Customer Input Needed? (p. 20)
3.3 What Input can the Customer Make? (p. 21)
3.3.1 Functional Requirements (p. 22)
3.3.2 Environmental Requirements (p. 22)
3.3.3 Ergonomic Requirements (p. 22)
3.3.4 User-Fit Requirements (p. 22)
3.3.5 Aesthetic Requirements (p. 22)
3.3.6 Emotional Requirements (p. 23)
3.4 How Can Customer Input Be Captured? (p. 23)
3.4.1 Rapid Manufacturing of Prototypes (p. 24)
3.4.2 Reverse Engineering (p. 25)
3.4.3 Interactive CAD Models (p. 25)
3.5 Using Customer Input within the Design Process (p. 26)
3.6 What Is Customisation? (p. 28)
3.7 Determining Which Features to Customise (p. 29)
3.8 Additional Customisation Issues (p. 30)
3.9 Case Study - Customising Garden Fork Handles (p. 31)
3.9.1 Customer Input Through the Use of Modelling Clay (p. 32)
3.9.2 Translation into a CAD Model (p. 32)
3.9.3 CAD Rendering (p. 33)
3.9.4 Verification of Functionality (p. 34)
3.10 Conclusions (p. 35)
References (p. 36)
4 CAD and Rapid Manufacturing (p. 39)
4.1 Introduction (p. 39)
4.2 CAD Background (p. 40)
4.2.1 History of CAD (p. 40)
4.2.2 NURB (p. 40)
4.3 Relations between CAD and Rapid Manufacturing (p. 43)
4.3.1 From NURB to Rapid Prototyping and Rapid Manufacturing (p. 43)
4.4 Future Developments Serving Rapid Manufacturing (p. 43)
4.4.1 Free Feature Modelling (p. 44)
4.4.2 Product Specific CAD (p. 44)
4.4.3 Repeating Features (p. 45)
4.5 CAD for Functionally Graded Materials (FGMs) (p. 48)
4.5.1 Voxel-Based FGMs (p. 49)
4.5.2 VPD System (p. 50)
4.5.3 Summary of FGMs (p. 53)
4.6 Conclusion (p. 54)
References (p. 54)
5 Emerging Rapid Manufacturing Processes (p. 55)
5.1 Introduction (p. 55)
5.2 Liquid-Based Processes (p. 58)
5.2.1 Stereolithography (p. 59)
5.2.2 Jetting Systems (p. 60)
5.2.3 Direct Light Processing Technologies (p. 61)
5.2.4 High-Viscosity Jetting (p. 61)
5.2.5 The Maple Process (p. 63)
5.3 Powder-Based Processes (p. 64)
5.3.1 Selective Laser Sintering (Polymers) (p. 64)
5.3.2 Selective Laser Sintering (Ceramics and Metals) (p. 65)
5.3.3 Direct Metal Laser Sintering (p. 66)
5.3.4 Three-Dimensional Printing (p. 66)
5.3.5 Fused Metal Deposition Systems (p. 67)
5.3.6 Electron Beam Melting (p. 68)
5.3.7 Selective Laser Melting (p. 68)
5.3.8 Selective Masking Sintering (p. 68)
5.3.9 Selective Inhibition Sintering (p. 70)
5.3.10 Electrophotographic Layered Manufacturing (p. 72)
5.3.11 High-Speed Sintering (p. 73)
5.4 Solid-Based Processes (p. 75)
5.4.1 Fused Deposition Modelling (p. 75)
5.4.2 Sheet Stacking Technologies (p. 78)
Acknowledgement (p. 79)
References (p. 79)
6 Materials Issues in rapid Manufacturing (p. 81)
6.1 Role of Materials in Rapid Manufacturing (p. 81)
6.2 Viscous Flow (p. 81)
6.3 Photopolymerization (p. 83)
6.4 Sintering (p. 84)
6.5 Infiltration (p. 91)
6.6 Mechanical Properties of RM Parts (p. 94)
6.7 Materials for RM Processes (p. 97)
6.8 The Future of Materials in Rapid Manufacturing (p. 98)
Acknowledgement (p. 99)
References (p. 99)
7 Functionally Graded Materials (p. 103)
7.1 Introduction (p. 103)
7.2 Processing Technologies (p. 104)
7.3 Rapid Manufacturing of FGM Parts - Laser Fusion (p. 106)
7.3.1 Liquid Phase Sintering (LPS) (p. 106)
7.3.2 LPS in Laser Processing Powders or FGMs (p. 107)
7.3.3 Issues with Laser - Material Interactions (p. 110)
7.4 Modelling and Software Issues (p. 111)
7.4.1 Compositional Profile (p. 111)
7.4.2 Software Issues (p. 112)
7.5 Characterisation of Properties (p. 113)
7.5.1 Thermal Properties (p. 114)
7.5.2 Mechanical Properties (p. 116)
7.6 Deposition Systems (p. 117)
7.6.1 Local Composition Control (p. 117)
7.7 Applications (p. 119)
7.7.1 Aerospace (p. 119)
7.7.2 Sporting Goods (p. 119)
7.7.3 Medical (p. 119)
Acknowledgement (p. 121)
References (p. 121)
8 Materials and Process Control for Rapid Manufacture (p. 125)
8.1 Introduction (p. 125)
8.2 Stereolithography (p. 126)
8.2.1 Viability for Series Rapid Manufacturing (p. 131)
8.3 Selective Laser Sintering (p. 132)
8.3.2 Viability for Series Rapid Manufacturing using SLS (p. 138)
8.4 Fused Deposition Modeling (p. 138)
8.4.1 Viability for Series Rapid Manufacturing (p. 141)
8.5 Metal-Based Processes (p. 142)
8.5.2 Fused Metal Deposition Systems (p. 142)
8.5.2 Viability for Series Rapid Manufacturing (p. 144)
8.5.3 Powder Bed Systems (p. 145)
8.5.4 Ultrasonic Consolidation (p. 145)
8.5.5 Viability for Direct Serial Manufacturing (p. 146)
References (p. 146)
9 Production Economics of Rapid Manufacture (p. 147)
9.1 Introduction (p. 147)
9.2 Machine Costs (p. 148)
9.3 Material Costs (p. 149)
9.4 Labour Costs (p. 150)
9.5 Comparing the Costs of Rapid Manufacture with Injection Moulding (p. 152)
References (p. 156)
10 Management and Implementation of Rapid Manufacturing (p. 159)
10.1 Introduction (p. 159)
10.2 Costs of Manufacture (p. 160)
10.3 Overhead Allocation (p. 160)
10.4 Business Costs (p. 160)
10.5 Stock and Work in Progress (p. 161)
10.6 Location and Distribution (p. 162)
10.7 Supply Chain Management (p. 164)
10.7.1 Lean (p. 165)
10.7.2 Agile (p. 167)
10.7.3 Leagility and Postponement (p. 167)
10.7.4 Impact of RM on Mass Customisation (p. 168)
10.7.5 RM and the Demand Chain (p. 169)
10.8 Change (p. 170)
10.9 Conclusions (p. 171)
References (p. 172)
11 Medical Applications (p. 175)
11.1 Introduction (p. 175)
11.2 Pre-Surgery RM (p. 176)
11.3 Orthodontics (p. 179)
11.4 Drug Delivery Devices (p. 181)
11.5 Limb Prosthesis (p. 183)
11.6 Specific Advances in Computer Aided Design (CAD) (p. 184)
11.7 In Vivo Devices (p. 185)
11.7.1 Fused Deposition Modelling (FDM) for In Vivo Devices (p. 186)
11.7.2 SLA (Stereolithography Apparatus) for In Vivo Devices (p. 187)
11.7.3 SLS for In Vivo Devices (p. 187)
11.7.4 3DP for In Vivo Devices (p. 188)
11.7.5 Other RM Processes for In Vivo Devices (p. 189)
References (p. 191)
12 Rapid Manufacturing in the Hearing Industry (p. 195)
12.1 The Hearing Industry (p. 195)
12.2 Manual Manufacturing (p. 196)
12.3 Digital Manufacturing (p. 197)
12.4 Scanning (p. 198)
12.5 Electronic Detailing (p. 199)
12.6 Electronic Modeling (p. 200)
12.7 Fabrication (p. 202)
12.8 Equipment (p. 203)
12.9 Selective Laser Sintering (SLS) (p. 203)
12.10 Stereolithography Apparatus (SLA) (p. 204)
12.11 Raster-Based Manufacturing (p. 206)
12.12 Materials (p. 207)
12.13 Conclusion (p. 208)
13 Automotive Applications (p. 211)
13.1 Introduction (p. 211)
13.2 Formula 1 (p. 212)
13.3 Cooling Duct (p. 213)
13.4 The 'Flickscab' (p. 213)
13.5 NASCAR (p. 215)
13.6 Formula Student (p. 215)
References (p. 219)
14 Rapid Manufacture in the Aeronautical Industry (p. 221)
14.1 Opportunity (p. 221)
14.2 Overview (p. 221)
14.3 Historical Perspective (p. 222)
14.4 Aeronautical Requirements for RM (p. 223)
14.5 Why RM Is Uniquely Suited to the Aeronautical Field (p. 223)
14.6 Acceptable Technologies (p. 225)
14.7 Qualifying RM Systems (p. 228)
14.7.1 Qualifying SLS at British Aerospace (BAe) (p. 229)
14.7.2 Qualifying SLS at Northrop Grumman (p. 229)
14.8 Summary (p. 231)
14.9 Case Studies (p. 231)
Reference (p. 231)
15 Aeronautical Case Studies using Rapid Manufacture (p. 233)
15.1 Introduction (p. 233)
15.2 Problem and Proposed Solution (p. 233)
15.3 Benefits of a Rapid Manufacture Solution (p. 235)
15.3.1 Design Flexibility Benefits (p. 235)
15.3.2 'No Tooling' Benefits (p. 236)
15.3.3 Systems Benefits (p. 237)
15.4 Pre-Production Program (p. 237)
15.5 Production (p. 238)
15.6 Summary (p. 239)
16 Space Applications (p. 241)
16.1 Introduction (p. 241)
16.2 Building the Team (p. 242)
16.3 Quality Assurance (p. 244)
16.4 How to 'Qualify' a Part Created Using This Process (p. 245)
16.5 Producing Hardware (p. 246)
17 Additive Manufacturing Technologies for the Construction Industry (p. 249)
17.1 Introduction (p. 249)
17.2 The Emergence of Freeform Construction (p. 250)
17.2.1 Applying Lessons front Rapid Manufacturing (p. 250)
17.2.2 Opportunities for Freeform Construction (p. 255)
17.3 Freeform Construction Processes: A Matter of Scale (p. 262)
17.3.1 Off-Site Processes (p. 263)
17.3.2 On-Site Processes (p. 265)
17.3.3 Off-World Processes (p. 267)
17.4 Conclusions (p. 271)
References (p. 272)
18 Rapid Manufacture for the Retail Industry (p. 275)
18.1 Introduction (p. 275)
18.2 Fascinating Technology with Little Consumer Knowledge (p. 275)
18.3 The Need for Rapid Prototyping to Change to Rapid Manufacturing (p. 276)
18.4 Rapid Manufacturing Retail Applications (p. 276)
18.4.1 Lighting (p. 276)
18.4.2 Three-Dimensional Textiles (p. 278)
18.5 Mass Customisation (p. 280)
18.5.1 Mass Customised Retail Products (p. 280)
18.5.2 Future Posibilities of Mass Customised RM Products (p. 280)
18.5.3 Limitations and Possibilities (p. 281)
18.6 Experimentation and Future Applications (p. 282)
Index (p. 283)

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