June 22, 2008
June 22, 2008
June 25, 2008
13.591.1 - 13.591.13
Experiences with the Design and Development of a Novel Rapid Product Manufacturing Technique in the Batch Production of Miniature Industrial Components
This paper presents a novel rapid product manufacturing technique that will reduce cost and compress time for delivery of products produced in batches. The technique is composed of four stages – digital prototype, computer aided engineering analysis, physical prototype and rapid tooling manufacturing system. The technique effectively integrates the contemporary advanced manufacturing technologies such as solid modeling, CAE, reverse engineering, rapid prototyping and rapid tooling in improving the product design, analysis, prototype, mould and production process. Example of products developed through this technique is also reported in the paper. The initial findings prove the potential of the technique in reducing the time and cost of product development and manufacturing in the quantity or batch production environment. This technique is experimented through the senior design project and proved highly effective in presenting opportunities for students in applying various state of the art product manufacturing technologies that they have learnt in their engineering technology curriculum.
Global competitions force manufacturers to constantly innovate new product manufacturing strategies in reducing product development cost and time. For example, Rapid Prototyping can cut new product development costs by up to 70% and the time to market by 90%.1 There are situations were the customer has requirement for a small quantity, say 25 numbers, of complex product (toy gun for a special game as an example) within a delivery time of 7 days. This type of production requirement falls into the category of batch or quantity production. And, this batch manufacturing of complex parts/product poses special challenge to manufacturers in meeting the target cost and delivery time. None of the contemporary technologies such as traditional manufacturing processes, Computer Numerical Control (CNC) machining or rapid prototyping will offer cost effective solution for this type of manufacturing. To solve this problem, the proposed novel technique of integrating new technologies such as 3D modeling, Computer Aided Engineering (CAE), Rapid Prototyping (RP) and Rapid Tooling (RT) must be considered. These stand alone new technologies have proven record of reducing product manufacturing cost and time. When these technologies are properly integrated the cumulative effect will be the optimum cost and time for batch manufacturing 2. Details of this rapid product manufacturing technique and the example of products manufactured by this technique are discussed in the subsequent sections.
Design of Integrated Product Manufacturing Technique
Customers demand high quality and reliable products that are cost effective and delivered on time. Contemporary manufacturers have the option of selecting optimum technologies or
Edinbarough, I., & Muniz, Y. (2008, June), Experiences With The Design And Development Of A Novel Rapid Product Manufacturing Technique In The Batch Production Of Miniature Industrial Components. Paper presented at 2008 Annual Conference & Exposition, Pittsburgh, Pennsylvania. https://peer.asee.org/3293
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