4.4 Manufacturing Processes
Essential idea:
Different manufacturing processes have been developed to innovate existing products and create new products.
Nature and Aims of Design
Nature of Design
Designers sometimes engineer products in such a way that they are easy to manufacture. Design for manufacture (DfM) exists in almost all engineering disciplines, but differs greatly depending on the manufacturing technologies used. This practice not only focuses on the design of a product’s components, but also on quality control and assurance. (1.11)
Aims
Aim 8: Advancements in 3D printing have resulted in the ability to have a 3D printer at home. Consumers can download plans for products from the internet and print these products themselves.
Guidance
As DP Design Technology student you should:
Additive techniques: paper-based rapid prototyping, laminated object manufacture (LOM), stereolithography
Wasting/subtractive techniques: cutting, machining, turning and abrading
Shaping techniques: moulding, thermoforming, laminating, casting, knitting, weaving
Joining techniques: permanent and temporary, fastening, adhering, fusing
Guidance:
Selecting appropriate manufacturing techniques based on material characteristics (form, melting/softening point), cost, capability, scale of production, desired properties
Advantages and disadvantages of different techniques
Design contexts where different manufacturing processes are used
Concepts and Principles
Design for Manufacturing
Design for Manufacturing (DfM) refers to the manufacturing process driving the some of the design design decisions. As such, designers design to optimize the process. For example, if a company already has plastic injection molding equipment, then the designer will design the product with that manufacturing process in mind.
When designers are selecting processes for manufacturing they should consider:
Material properties
Cost
Scale of production
in order to determine the ideal process to meet their needs.
Scale of Production
Cost associated for tooling, manufacturing machines and equipment
Time required for processing
Energy consumption
Availability of material and cost of material
Capabilities required to processes material
Product dimensions and size
Design tolerances
Waste produced by the process
Maintenance costs
The website Engineering Clicks provides a good overview for selecting the correct process for design
Manufacturing techniques can be divided into 4 broad categories:
Methods that modify the shape of the material using heat, pressure, and other mechanical manipulation.
Selecting a manufacturing technique
Books adn resources in classrooms
decision matrix or flow chart