Advanced Manufacturing Nature 2017 Ann Vallie

What is Advanced Manufacturing defined? Advanced Manufacturing technology is “a family of activities that (a) depend on the use and coordination of information, automation, computation, software, sensing, and networking, and/or (b) make use of cutting edge materials and emerging capabilities enabled by the physical and biological sciences, for example nanotechnology, chemistry, and biology. This involves both new ways to manufacture existing products, and especially the manufacture of new products emerging from new advanced technologies.”

Advanced Manufacturing process video https://www.youtube.com/watch?v=meR-cV0ifIM

What is a prototype model? It is a systems development method (SDM) in which a prototype (an early approximation of a final system or product) is built, tested, and then reworked as necessary until an acceptable prototype is finally achieved from which the complete system or product can now be developed. This model works best in scenarios where not all of the project requirements are known in detail ahead of time. It is an iterative, trial-and-error process that takes place between the developers and the users.

Rapid prototyping videos Sketching and paper prototyping https://www.youtube.com/watch?v=JMjozqJS44M Digital prototyping https://www.youtube.com/watch?v=KWGBGTGryFk Native prototyping https://www.youtube.com/watch?v=lusOgox4xMI

What is a CAD design? CAD, or computer-aided design and drafting (CADD), is the use of computer technology for design and design documentation. CAD software replaces manual drafting with an automated process. If you work in the architecture, MEP, or structural engineering fields, you've probably used 2D or 3D CAD programs. https://www.youtube.com/watch?v=ZDeLwFwnFKg

What is CAD software? CAD design software is used in almost every industry, in projects as wide-ranging as landscape design, bridge construction, office building design, and movie animation. With 2D or 3D CAD programs, you can perform a variety of tasks: you can create a 3D model of a design, apply material and light effects, and document the design with dimensions and other annotations. https://www.youtube.com/watch?v=ETz67OUsXC0

Building design Product design Infrastructure design Manufacturing design Building design -professionals working in architecture, construction, MEP engineering, and structural engineering, and by building owners, operators, and managers. Industry-specific AutoCAD applications and Revit-based software offer specialized tools for building design processes, while Architecture, Engineering & Construction Collection unites these products, Product design - CAD design software is used throughout the product development cycle. From concept to manufacturing, Autodesk software is used to create consumer products, industrial machinery, and building products and equipment. Infrastructure design - CAD design tools such as AutoCAD Civil 3D and InfraWorks software are used to create intelligent 3D models and engineering drawings for land development, transportation, utilities and telecom, and water and wastewater projects. Manufacturing design - CAD design systems in 2D and 3D are used to visually draft plant or factory layout designs.

Animation design Electrical design Animation design - Create compelling visual effects for films, games, or television shows with CAD design programs. Electrical design - Autodesk electrical design and electrical control design software addresses the specific workflows for electrical controls systems designers.

What is 3D printing? It is an additive manufacturing process that creates a physical object from a digital design. There are different 3D printing technologies and materials you can print with, but all are based on the same principle: a digital model is turned into a solid three-dimensional physical object by adding material layer by layer. SLA-1, the first 3D printer invented by Chuck Hull in 1983

Example types of materials 3D printers use Prototyping plastic High detail resin SLS nylon Rigid opaque plastic Fiber-Reinforced Nylon Rubber-like plastic Prototyping plastic - Affordable, durable and widely available plastics like ABS and PLA. High detail resin - Intricate designs and sculptures with a smooth surface finish. SLS nylon - Functional prototypes and end-use parts from laser sintered nylon. Rigid opaque plastic - Realistic prototypes with excellent details and high accuracy. Fiber-Reinforced Nylon - Engineering parts as strong as metal for the price of plastic. Rubber-like plastic - Simulate rubber with various levels of elasticity.

Transparent plastic Stimulated ABS Full Color Sandstone Industry metals Transparent plastic - See-through parts and prototypes. Stimulated ABS - High precision functional (injection) molds with the toughness of ABS. Full Color Sandstone - Photo-realistic full color (scale) models and sculptures. Industry metals - Industrial metals and alloys for prototypes and end-use parts.

9 Basic Types of 3D Printers 1. FDM (Fused Deposition Modeling) https://www.youtube.com/watch?list=PLdLJV6tsi3AC- VhITL9Sx5by9x9twyYgb&v=lkygiH6sjoM 2. SLA (Stereolithography) https://www.youtube.com/watch?list=PLwr52gp_JAaeo4d9Q3nYeWuYNmoytBktf&v=8a2xNa AkvLo 3. DLP (Digital Light Processing) https://www.youtube.com/watch?v=sfGrWZwiRFU 4. SLS (Selective Laser Sintering) https://www.youtube.com/watch?v=O2thSsQrZUM 5. SLM (Selective Laser Melting) https://www.youtube.com/watch?v=SQdn_TvryeE FDM is the most common 3D printing method used in desktop 3D printing. Thermoplastic filament is heated and extruded through an extrusion head that deposits the molten plastic in X and Y coordinates, while the build table lowers the object layer by layer in the Z direction. SLA works by exposing a layer of photosensitive liquid resin to a UV-laser beam so that the resin hardens and becomes solid. Digital Light Processing (DLP) and Stereolithography have a lot in common. Both types of 3D printers use liquid photopolymers. You might have heard of these “resins”. DLP and SLA printers cure them by applying light to it. SLA does that with a laser, DLP with a special projector. SLS is similar to SLA, but the key difference is that this type of 3D printer uses powdered material in the build area instead of liquid resin. A laser is used to selectively sinter a layer of granules, which binds the material together to create a solid structure. When the object is fully formed, it’s left to cool in the machine before being removed. SLM is sometimes regarded as a subcategory of the SLS 3D printer type, where SLM uses a high-powered laser beam to fully melt metallic powders into solid three-dimensional parts.

Cont. 6. EBM (Electron Beam Melting) 7. LOM (Laminated Object Manufacturing) https://www.youtube.com/watch?v=bnn-ACoMw4w 8. BJ (Binder Jetting) https://www.youtube.com/watch?v=DDeleRiIiQU 9. Material Jetting (MJ) / Wax Casting https://www.youtube.com/watch?v=czr8-Y5Cb9E In contrast to SLM, the EBM technique uses a computer-controlled electron beam under high vacuum to fully melt the metallic powder at high temperatures up to 1000 °C. This type of 3D printer can use metals like pure titanium, Inconel718, and Inconel625 to fabricate aerospace parts and medical implants. But while the 3D printer technology is exciting, it’s currently very slow and very expensive. LOM uses layers of adhesive-coated paper, plastic or metal laminates, which are fused under heat and pressure and shaped by cutting with a computer controlled laser or knife. This is sometimes followed by machining and drilling. The 3D object is created layer-by-layer, and after the excess material is cut away, the object can be sanded or sealed with paint. LOM is one of the most affordable and fastest 3D printing methods available to create relatively large parts. It also allows for full-color 3D printed objects. Binder Jetting is an additive manufacturing process. This type of 3D printer uses two materials: a powder based (often gypsum) material and a bonding agent. The agent acts as an adhesive between powder layers. Usually, the binder is extruded in liquid form from a printhead – just think of a regular inkjet 2D printer. After a layer is finished, the build plate is lowered and the process repeated. The Material Jetting technology is better known as”wax casting”. There‘s no inventor per se – it’s a technique used by jewelers since centuries. Lost wax casting (or investment casting) is a production process that mainly allows you to produce customizable jewelry of very high quality in various metals. But with 3D printing, there’s finally a process to automate wax casting

Activity 1 Modern Manufacturing: Do You Have What It Makes?

Activity 2 Balloon Powered Car design challenge

Activity 3 Introduction to 3D printing- Design/Print a Board Game Piece