Rapid manufacturing : an industrial revolution for the digital age /
editors, N. Hopkinson, R.J.M. Hague, and P.M. Dickens.
Chichester, England : John Wiley, 2006.
xviii, 285 p.
0470016132 (cloth : alk. paper), 9780470016138 (cloth : alk. paper)
More Details
Chichester, England : John Wiley, 2006.
0470016132 (cloth : alk. paper)
9780470016138 (cloth : alk. paper)
Online version licensed for access by U. of T. users.
catalogue key
Includes bibliographical references and index.
A Look Inside
This item was reviewed in:
SciTech Book News, March 2006
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Back Cover Copy
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.
Bowker Data Service Summary
This text addresses the academic fundamentals of rapid manufacturing as well as focusing 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.
Table of Contents
List of Contributorsp. xiii
Editorsp. xv
Forewordp. xvii
Introduction to Rapid Manufacturingp. 1
Definition of Rapid Manufacturingp. 1
Latitude of Applicationsp. 2
Design Freedomp. 2
Economic for Volumes down to Onep. 3
Overcoming the Legacy of Rapid Prototypingp. 3
A Disruptive Technologyp. 4
A Breakdown of the Field of Rapid Manufacturingp. 4
Unlocking the Design Potential of Rapid Manufacturingp. 5
Introductionp. 5
Potential of Rapid Manufacturing on Designp. 7
Conventional 'Design for Manufacture' (DFM)p. 7
Conventional Design for Assembly (DFA)p. 8
Impact of RM on DFM and DFAp. 8
Geometrical Freedomp. 9
Design Complexity/Optimisationp. 10
Part Consolidationp. 11
Body Fitting Customisationp. 12
Multiple Assemblies: Textilesp. 13
Material Combinationsp. 16
Summaryp. 17
Referencesp. 18
Customer Input and Customisationp. 19
Introductionp. 19
Why Is Customer Input Needed?p. 20
What Input can the Customer Make?p. 21
Functional Requirementsp. 22
Environmental Requirementsp. 22
Ergonomic Requirementsp. 22
User-Fit Requirementsp. 22
Aesthetic Requirementsp. 22
Emotional Requirementsp. 23
How Can Customer Input Be Captured?p. 23
Rapid Manufacturing of Prototypesp. 24
Reverse Engineeringp. 25
Interactive CAD Modelsp. 25
Using Customer Input within the Design Processp. 26
What Is Customisation?p. 28
Determining Which Features to Customisep. 29
Additional Customisation Issuesp. 30
Case Study - Customising Garden Fork Handlesp. 31
Customer Input Through the Use of Modelling Clayp. 32
Translation into a CAD Modelp. 32
CAD Renderingp. 33
Verification of Functionalityp. 34
Conclusionsp. 35
Referencesp. 36
CAD and Rapid Manufacturingp. 39
Introductionp. 39
CAD Backgroundp. 40
History of CADp. 40
NURBp. 40
Relations between CAD and Rapid Manufacturingp. 43
From NURB to Rapid Prototyping and Rapid Manufacturingp. 43
Future Developments Serving Rapid Manufacturingp. 43
Free Feature Modellingp. 44
Product Specific CADp. 44
Repeating Featuresp. 45
CAD for Functionally Graded Materials (FGMs)p. 48
Voxel-Based FGMsp. 49
VPD Systemp. 50
Summary of FGMsp. 53
Conclusionp. 54
Referencesp. 54
Emerging Rapid Manufacturing Processesp. 55
Introductionp. 55
Liquid-Based Processesp. 58
Stereolithographyp. 59
Jetting Systemsp. 60
Direct Light Processing Technologiesp. 61
High-Viscosity Jettingp. 61
The Maple Processp. 63
Powder-Based Processesp. 64
Selective Laser Sintering (Polymers)p. 64
Selective Laser Sintering (Ceramics and Metals)p. 65
Direct Metal Laser Sinteringp. 66
Three-Dimensional Printingp. 66
Fused Metal Deposition Systemsp. 67
Electron Beam Meltingp. 68
Selective Laser Meltingp. 68
Selective Masking Sinteringp. 68
Selective Inhibition Sinteringp. 70
Electrophotographic Layered Manufacturingp. 72
High-Speed Sinteringp. 73
Solid-Based Processesp. 75
Fused Deposition Modellingp. 75
Sheet Stacking Technologiesp. 78
Acknowledgementp. 79
Referencesp. 79
Materials Issues in rapid Manufacturingp. 81
Role of Materials in Rapid Manufacturingp. 81
Viscous Flowp. 81
Photopolymerizationp. 83
Sinteringp. 84
Infiltrationp. 91
Mechanical Properties of RM Partsp. 94
Materials for RM Processesp. 97
The Future of Materials in Rapid Manufacturingp. 98
Acknowledgementp. 99
Referencesp. 99
Functionally Graded Materialsp. 103
Introductionp. 103
Processing Technologiesp. 104
Rapid Manufacturing of FGM Parts - Laser Fusionp. 106
Liquid Phase Sintering (LPS)p. 106
LPS in Laser Processing Powders or FGMsp. 107
Issues with Laser - Material Interactionsp. 110
Modelling and Software Issuesp. 111
Compositional Profilep. 111
Software Issuesp. 112
Characterisation of Propertiesp. 113
Thermal Propertiesp. 114
Mechanical Propertiesp. 116
Deposition Systemsp. 117
Local Composition Controlp. 117
Applicationsp. 119
Aerospacep. 119
Sporting Goodsp. 119
Medicalp. 119
Acknowledgementp. 121
Referencesp. 121
Materials and Process Control for Rapid Manufacturep. 125
Introductionp. 125
Stereolithographyp. 126
Viability for Series Rapid Manufacturingp. 131
Selective Laser Sinteringp. 132
Viability for Series Rapid Manufacturing using SLSp. 138
Fused Deposition Modelingp. 138
Viability for Series Rapid Manufacturingp. 141
Metal-Based Processesp. 142
Fused Metal Deposition Systemsp. 142
Viability for Series Rapid Manufacturingp. 144
Powder Bed Systemsp. 145
Ultrasonic Consolidationp. 145
Viability for Direct Serial Manufacturingp. 146
Referencesp. 146
Production Economics of Rapid Manufacturep. 147
Introductionp. 147
Machine Costsp. 148
Material Costsp. 149
Labour Costsp. 150
Comparing the Costs of Rapid Manufacture with Injection Mouldingp. 152
Referencesp. 156
Management and Implementation of Rapid Manufacturingp. 159
Introductionp. 159
Costs of Manufacturep. 160
Overhead Allocationp. 160
Business Costsp. 160
Stock and Work in Progressp. 161
Location and Distributionp. 162
Supply Chain Managementp. 164
Leanp. 165
Agilep. 167
Leagility and Postponementp. 167
Impact of RM on Mass Customisationp. 168
RM and the Demand Chainp. 169
Changep. 170
Conclusionsp. 171
Referencesp. 172
Medical Applicationsp. 175
Introductionp. 175
Pre-Surgery RMp. 176
Orthodonticsp. 179
Drug Delivery Devicesp. 181
Limb Prosthesisp. 183
Specific Advances in Computer Aided Design (CAD)p. 184
In Vivo Devicesp. 185
Fused Deposition Modelling (FDM) for In Vivo Devicesp. 186
SLA (Stereolithography Apparatus) for In Vivo Devicesp. 187
SLS for In Vivo Devicesp. 187
3DP for In Vivo Devicesp. 188
Other RM Processes for In Vivo Devicesp. 189
Referencesp. 191
Rapid Manufacturing in the Hearing Industryp. 195
The Hearing Industryp. 195
Manual Manufacturingp. 196
Digital Manufacturingp. 197
Scanningp. 198
Electronic Detailingp. 199
Electronic Modelingp. 200
Fabricationp. 202
Equipmentp. 203
Selective Laser Sintering (SLS)p. 203
Stereolithography Apparatus (SLA)p. 204
Raster-Based Manufacturingp. 206
Materialsp. 207
Conclusionp. 208
Automotive Applicationsp. 211
Introductionp. 211
Formula 1p. 212
Cooling Ductp. 213
The 'Flickscab'p. 213
NASCARp. 215
Formula Studentp. 215
Referencesp. 219
Rapid Manufacture in the Aeronautical Industryp. 221
Opportunityp. 221
Overviewp. 221
Historical Perspectivep. 222
Aeronautical Requirements for RMp. 223
Why RM Is Uniquely Suited to the Aeronautical Fieldp. 223
Acceptable Technologiesp. 225
Qualifying RM Systemsp. 228
Qualifying SLS at British Aerospace (BAe)p. 229
Qualifying SLS at Northrop Grummanp. 229
Summaryp. 231
Case Studiesp. 231
Referencep. 231
Aeronautical Case Studies using Rapid Manufacturep. 233
Introductionp. 233
Problem and Proposed Solutionp. 233
Benefits of a Rapid Manufacture Solutionp. 235
Design Flexibility Benefitsp. 235
'No Tooling' Benefitsp. 236
Systems Benefitsp. 237
Pre-Production Programp. 237
Productionp. 238
Summaryp. 239
Space Applicationsp. 241
Introductionp. 241
Building the Teamp. 242
Quality Assurancep. 244
How to 'Qualify' a Part Created Using This Processp. 245
Producing Hardwarep. 246
Additive Manufacturing Technologies for the Construction Industryp. 249
Introductionp. 249
The Emergence of Freeform Constructionp. 250
Applying Lessons front Rapid Manufacturingp. 250
Opportunities for Freeform Constructionp. 255
Freeform Construction Processes: A Matter of Scalep. 262
Off-Site Processesp. 263
On-Site Processesp. 265
Off-World Processesp. 267
Conclusionsp. 271
Referencesp. 272
Rapid Manufacture for the Retail Industryp. 275
Introductionp. 275
Fascinating Technology with Little Consumer Knowledgep. 275
The Need for Rapid Prototyping to Change to Rapid Manufacturingp. 276
Rapid Manufacturing Retail Applicationsp. 276
Lightingp. 276
Three-Dimensional Textilesp. 278
Mass Customisationp. 280
Mass Customised Retail Productsp. 280
Future Posibilities of Mass Customised RM Productsp. 280
Limitations and Possibilitiesp. 281
Experimentation and Future Applicationsp. 282
Indexp. 283
Table of Contents provided by Ingram. All Rights Reserved.

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