Design for Advanced Manufacturing: Technologies and Processes

Introduction
Part 1 Manufacturing with Lasers
1.1 Overview of Laser Manufacturing Processes
Reference
1.2 Laser Cutting
Materials
Equipment Capabilities
Design Considerations
1.3 Laser Surface Texturing
Process Physics
Why Use Laser Texturing?
Design Considerations
Material Suitability
Laser versus Electron Beam
Continuous versus Pulsed Operation
Surface Topography
Polishing Limitations
Structuring Limitations
Cost
References
1.4 Laser Ablation for Cleaning, Decoating, and Surface Preparation
Basic Science of Laser Ablation
Surface Preparation in Manufacturing
Implementation Considerations
Applications Where Laser Ablation Works Best
Applications Where Laser Ablation May or May Not Bring Important Benefits
Manual versus Robotic Laser Ablation
Precautions and Safety
1.5 Laser Hardening
Process
Applicable Lasers
Laser Hardening Materials
Grain Size
Hardening Process Comparisons
Application Examples
Laser Hardening of Dies and Tooling
Laser Hardening of Gears
Laser Hardening of Machine Parts
Laser Hardening of Cast Iron
References
1.6 Laser Welding of Metals
Applications
Equipment
Materials
Design Considerations
References
1.7 Laser Welding of Plastics
Contour Welding
Simultaneous
Quasi-Simultaneous
Mask
Line
Unique Variations
Applications
Materials Selection
Joint Design
Design Considerations
References
1.8 Designing for Laser Soldering
The Process
Typical Characteristics and Applications
Economics
Suitable Materials
Design Recommendations
Through-Hole Pad Design
Lap Joint Pad Design
Connector Selection
Fixturing
Lead-to-Hole Ratio
1.9 Design for Laser Cladding
The Laser Cladding Process
Laser Cladding and Conventional Welding
Laser Cladding with Powder versus Wire
Laser Cladding with Powder
Laser Cladding with Wire
Applications and Cladding Variables
Filler Materials
Laser Cladding Production Performance
1.10 Laser Marking and Engraving
Laser Marking
Materials That Can Be Marked
Selecting a Laser
Marking Metals
Anneal Marking
Engraving and Etching
Plastic, Glass, Coated, and Paper Marking
Marking on Painted Surfaces
1.11 Laser-Assisted Forming
Laser Forming
Laser-Assisted Forming
Laser-Assisted Micro Forming
References
1.12 Laser Peening
Laser Peening Process
Typical Characteristics and Applications
Residual Stress Magnitude and Depth
Residual Stress Stability
Surface Roughness Effects
Material Properties
Compensating Stresses and Deformation
Common Applications
Economics
General Process Design Considerations
Design Methodology
Pattern Size and Location
Intensity and Coverage
Suitable Materials
Detailed Design Considerations
Variations Based on Supplier
Intensity and Coverage Specification
Patch Size and Location on Drawings
Processing of Thin Sections and Shot Orders
Minimum Thickness
Part 2 Manufacturing with Additive Processes
2.1 Overview of Additive Manufacturing Processes
Overview of Primary Additive Manufacturing Technologies
General Design Considerations for Additive Manufacturing
References
2.2 Binder Jetting
The Process and Materials
Typical Characteristics and Applications
As Bonded
Lightly Sintered
Sintered and Infiltrated
Highly Sintered
Advantages of Binder Jetting
Economics
General Design Considerations
Suitable Materials
Detailed Design Considerations
Wall Thickness
Uniform Wall Thickness
Inside Edges
Interior Holes
Part Connections
2.3 Directed Energy Deposition
Metals
Applications
Design Issues
References
2.4 Material Extrusion
Applications
Considerations
References
2.5 Designing for Material Jetting Additive Processes
Machines
Materials
Base Materials
Composite Materials
Support Materials
Process Variable Impact on Part Quality
Minimum Feature Size and Accuracy
Surface Roughness
Stair-Stepping
Process Variable Impact on Material Properties
Tensile Properties
Fatigue Properties
Post-Processing Impact on Design Feasibility
Internal Cavities
Support Removal from Channels
Feature Survivability
General Guidelines for Material Jetting
References
2.6 Design for Powder Bed Fusion of Polymer Parts
Machines
Materials
The Influence of Process Variables on Part Properties
Mechanical Properties of Polymer Parts
Dimensioning Polymer Parts
General Design Considerations for Polymer Powder Bed Fusion
References
2.7 Design for Powder Bed Fusion of Metal Parts
Machines
Materials
Process Planning
Time and Cost Considerations
Quality Considerations
Mechanical Properties of Parts
Supporting Infrastructure
References
2.8 Polymer Laminate Technology
2.9 Accumulative Roll Bonding
The Process
Process Steps
ARB Applications
Limitations of the Process
Comparison of the Composite Material with Single-Material Sheet
2.10 Ultrasonic Lamination Technology
The Process
Characteristics and Applications
Dissimilar Metals
Embedding
Complicated Geometry
Economics
Materials Suitable to This Process
Specific Design Recommendations
2.11 Vat Photopolymerization: An Additive Process
The Process
Technology and Process Controls
Vat Photopolymerization: Systems
Geometries and Tolerances
Applications
Starting a Project
2.12 Hybrid Additive Process
The Process
Multiple Additive Processes on a Common Platform
Additive Plus Subtractive
Additive Plus Assembly Process on a Common Platform
Miscellaneous Adaptations
Electroforming over Stereolithography
Design Considerations
Part 3 Manufacturing Micro Parts and Micro Features
3.1 Micro Manufacturing: An Overview
Definition of “Micro Manufacturing”
Applications of Micro Manufacturing
Micro versus Conventional Manufacturing
Micro Machines and Machines for Micro Work
Processes
Materials
Research
Seeing and Measuring
Testing and Acceptance
People
Facilities
Services
Software
Design
3.2 Micro Mechanical Drilling
Introduction
Defining the Limits
Characteristics of Good Micro Drills
Starting the Hole
Operating Parameters
Machine Tool Requirements
3.3 Micro Milling
Basic Limitations
Materials Machined
Cutters
Coatings
Applications
Machines
Design Issues
References
3.4 Designing for the Swiss Screw Machine
Introduction
Process
Characteristics
Economics
Materials
Design Issues
3.5 Designing for Turning Micro Parts
Micro Lathes
Micro Lathe Capabilities for Micro- and Nano-Size Products—Research-Level Capabilities
Cutting Tool Challenges
Micro and Nano Turned Materials
References
3.6 Design Considerations for Laser Micro Machining
Laser Details
Product Considerations
Laser Software Considerations
Examples of Micro Machining
3.7 Micro Electrical Discharge Machining
Solid Electrode EDM
Wire Electrical Discharge Machining
Wire Electrical Discharge Grinding
Electrochemical Discharge Machining
Materials Machined
Equipment
Applications
Design Considerations
References
3.8 Precision Electrochemical Micro Machining
The Process and Capabilities
Process Principles
Electrolyte Type and Concentration
PECM System
Electrochemical Tooling
Cathode Oscillation
Electrolyte Flow
Power Supply
PECM Equipment
Process Capabilities
Some Typical Examples of PECM Parts
Example 1: Rotary Shaver Head
Example 2: High-Precision Gears
Example 3: Diesel Valve Plates
Summary
3.9 Electrochemical Micro Deburring
The Process
Process Principles
Tooling—Cathode and Anode Fixtures
Anode (Workpiece)
Cathode (Tool)
Fixtures
Electrolyte
Process Capabilities
Equipment
ECD Examples
ECD Example 1: Aluminum Manifold
ECD Example 2: Gear-Edge Deburring
ECD Example 3: Air Bag Housing
Summary
3.10 Electrochemical Discharge Machining
Introduction
Working Principle of ECDM
Material Removal Modes in ECDM
Process Characteristics of ECDM
Types of ECDM
Chemical Reactions in ECDM
Application Areas in ECDM
Capabilities of ECDM
References
3.11 Micro Wire Electrical Discharge Grinding
References
3.12 Electron Beam Drilling
Physical Part Size Limitations
Technology Applications
3.13 Electron Beam Polishing
3.14 Designing for Chemical Mechanical Polishing
The Process
Application of the Process
Enhanced Manufacturability of MST
Higher-Order CMP Effects
CMP Limitations
Materials
Critical Process Parameters for the Designer
Acknowledgments
Reference
3.15 Micro Ultrasonic Machining
USM Shapes and Tools
Workpiece Materials
Equipment
Process Variations
References
3.16 Cylindrical Micro Grinding
Process
Characteristics and Applications
Micro Size
Materials
Tolerances
Design Recommendations
Economics of Micro Grinding
3.17 Grinding with Mechanical Micro Tools
Introduction
Making the Tools
Machines for Micro Grinding
Capabilities of the Process
Other Processes
References
3.18 Micro Coining
References
3.19 Magnetic Abrasive Finishing
The Magnetic Abrasive Finishing Process
Characteristics and Applications of the Resulting Product
Materials Suitable to MAF
Specific Design Recommendations
References
3.20 Designing for Micro Abrasive Waterjet Machining
The Process
Relationship to Other Micro Cutting Methods
Abrasive Waterjet Generation and Cutting
Micro Abrasive Waterjet Machining Centers
Workpiece Holding
Human Machine Interface and Control System
Comprehensive CAM Software
Ideal Job Shop Micro Machining Tool
Future Developments
3.21 Photochemical Machining for Micro Parts
Process and Technology
Characteristics, Applications, and Limitations of the Resulting Product
Economics
Materials Suitable for This Process
Specific Design Recommendations and Issues
3.22 Micro Molding Overview
Applications for Micro Molded Parts
Types of Micro Molding
Small, Miniature, and Micro
Two-Shot Micro Molding
Insert Micro Molding
Lead Frame Micro Molding
Micro Overmolding
Enhancing Success in Micro Molding
Geometry and Material Selection
Materials
Part Size
Feature Size
Challenges
Quality and Critical Features
3.23 Micro Metal Powder Injection Molding
Micro MIM Materials
Parts and Features
Equipment
Design Considerations
References
3.24 Micro Stamping
The Impact of Part Design
Materials
Design
References
3.25 Designing for Micro Hot Embossing
The Process
Fabrication of Molds for Micro Hot Embossing
Micro Hot Embossing of Thermoplastics
Typical Applications
Materials Suitable to This Process
Materials for Mold/Stamp Fabrication
Thermoplastic Materials for Hot Embossing
Production Quantities
Equipment
Design Recommendations
Layout Design
Process Design
Process Recommendations
3.26 Roll-to-Roll Micro Embossing
Thermal Processes
Cold Embossing
UV Resist-Based Fabrication
Equipment
References
3.27 Laser-Assisted Micro Fabrication
Laser-Assisted Cutting and Grinding
Laser-Assisted Forming
Laser-Assisted Deep Drawing
Laser-Assisted Hot Embossing
Laser Chemical Vapor Deposition
Pulsed Laser Deposition
Laser Chemical Etching
Laser-Enhanced Electroplating
Laser-Based Combined Annealing and Texturing
3D Printing Laser Finishing
Laser-Assisted Ablation + Printing
References
3.28 Micro Extrusion
Process
Processing Equipment
Micro Extruded Sizes
Shapes
Materials
Product Cross Sections
Longitudinal Sections
Surfaces
Economics
3.29 Chemical Vapor Deposition
Materials Deposited
3.30 Magnetorheological Finishing
References
3.31 Micro Wire Products
Processes
Materials
Applications
Design Considerations
References
3.32 Micro Electroforming
Laser-Evolved Electroforming (LEEF)
Materials
Emerging Aspects
Design Considerations
References
3.33 Manufacturing with LIGA
LIGA Materials
LIGA Products
Alternative LIGA Approaches
Design Restraints
References
3.34 Deburring Micro Parts
Basic Issues
Design Issues
Preventing Burrs
Minimizing Burrs
Deburring Processes for Micro Features
Magnetic Abrasive Finishing
Ultrasonic Deburring
Electrochemical Deburring
Electropolishing
Electrical Discharge Deburring
Flat Lapping
Micro Blasting (Abrasive Micro Jet Machining)
Centrifugal Barrel Deburring
Coining
Hot Embossing
Plasma Glow Deburring
Laser Deburring
Manual Deburring
Chlorine Gas Deburring
Processes Not Usually Considered as Deburring Processes
Measuring Micro Burrs
The Optimum Approach
References
3.35 Electrospinning
Fiber Characteristics
Co-electrospinning
Nanofiber Applications
Equipment
3.36 Designing for Resistance Welding Micro Parts
Resistance Welding Basics
Resistance Welding for Micro Joining Small Parts
Micro Joining Design Challenges
Precise Control Is the Key to Meeting Micro Joining Challenges
Electrode Design and Tooling
Three Areas to Consider When Designing Micro Parts for Resistance Welding
Material Properties
Surface Conditions
Physical Part Design
Cycle Times
Heat Balance and Specific Design Recommendations
Advances in Micro Resistance Welding Technology on the Horizon
Summary
3.37 Practical Guide to Laser Micro Welding
Introduction
Laser Micro Welding Basics
Laser Types for Micro Welding
Selecting the Correct Material for Weldability and Functionality—Metals
Welding Dissimilar Metals
Metal Plating Affects Welding Process
Selecting the Correct Material for Weldability and Functionality—Plastics
Joint Design, Part Tolerances, and Fit-up
Steps for Ensuring an Optimal Laser Micro Welding Process
3.38 Micro Electron Beam Welding
3.39 Micro Welding for Assembly and Rapid Turnaround Changes
Micro TIG versus Laser
Prototyping and Iterative Design
3.40 Ultrasonic Micro Welding
Process
Polymer Parts
Metal Joining
Joining Metals to Nonmetals
Key Design Considerations
References
3.41 Micro Adhesive Bonding
Process
Adhesive Bonding
Equipment
Hot Melt Approaches
UV Curable Adhesives
Additional Design Thoughts
References
3.42 Micro Blasting
Abrasives
Nozzles
Key Variables
Important Notes
Controlled Erosion Overview
Materials Suitable to the Controlled Erosion Process
Abrasive Characteristics
Appropriate Applications: Masking versus Direct Machining
Selective Cleaning
Materials Suitable to Cleaning
Brittle Coating Removal: CIGS from Molybdenum
Precision Deburring
Part Material and Abrasive Selection
Manual versus Automation
Surface Texturing
Ra or Sa
Coverage
Surface Area Ratio
Shape
Materials Suitable to the Process
Abrasive Characteristics
Important Notes
Example: Dental Implants
3.43 Micro Part Inspection
Handling
Inspection Approaches
Touch Probing
Hard Gaging
Microscopes
Optical Comparators
White Light Systems
Laser Scanners
Video Systems
Digital X-Ray
CT Scanning
Other Approaches
Environment
Validating the Process Rather Than the Product
References
3.44 Advanced Additive Manufacturing: The MICA Freeform Process
MICA Freeform Process
Capabilities of the MICA Freeform Process
Unique Features
Precision Holes
Micro Channels
Micro Bosses and Ribs
Undercuts
Assemblies and Mechanisms
Materials
Design Recommendations
When to Use MICA Freeform
3.45 Micro Stereolithography
Applications
References
3.46 Micro Electromechanical Systems
MEMS Manufacture
Designing for MEMS
Design for MEMS Actuation
Sensors
What a New Designer Should Do When MEMS Design Seems Applicable
Constraints
References
3.47 Origami Micro Fabrication
State of the Art
Manufacturing Approaches
Simple Shape Changes
Complex Changes and Abilities
Design to Accomplish Change
References
3.48 Ion Beam Machining
Design Freedom
References
3.49 Dip-Pen/Polymer-Pen Technology
References
3.50 Capillary Forming
Simple Capillary Action
Carbon Nanotube Process
Design Considerations
References
3.51 Handling Micro Parts
Handling Solutions
Manual Approaches
Automated Mechanical Approaches
Magnetics
Electrostatics
Surface Tension
Vacuum and Air Pressure
Adhesives
Thermal Approaches
Lasers
Bernoulli Effect
Sonics Approaches
Acoustic Approaches
Vibratory Approaches
Fixturing
Biological Processes
Specific Design Considerations
References
3.52 Assembly of Micro Parts
Positioning
Joining
Contamination
Pop-Up Design
Self-Assembly
Biomedical Issues
Shape Memory Alloys
References
Index