CUTTING EDGE TECHNOLOGIES IN MANUFACTURING

8/4/2019 CUTTING EDGE TECHNOLOGIES IN MANUFACTURING

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A PARADIGM SHIFT

Presented by

Himanshu BharadwajII yr Mechanical

IIT Powai

Lara SewlaniII yr Mechanical

IIT Powai



Evolution in India Recent cutting edge technologies Rapid prototyping

Major rapid prototyping techniques Comparative view Applications Agile manufacturing

Agile manufacturing + Rapid Prototyping Agile in electronics The paradigm shift Conclusion



1950-1960 : Initial phase of building theindustrial foundation

By 1990 : liberalized sector

By 2010 : 2nd largest global manufacturinghub



Rapidprototyping

High speedmachining

Automation &robotics

nanotechnology

Recenttechnologies



Assembly using three-dimensional computer aideddesign (CAD)

Referred to as solid free-form or layered manufacturing

Manufacturingprocesses

Subtractiveprocesses

Shaping Milling Machining

Additiveprocess

Rapid

prototyping



1. To increase effective communication

2. To decrease development time.

3. To decrease costly mistakes.

4. To test the products.

5. To create ideal models for tooling.



1. A CAD model is constructed.2. The material is processed by creating sliced layers

of the model.3. After each layer model is then lowered by the

thickness of the previous layer.4. After completion the model and any supports are

removed.5. Model is then finished and cleaned.



31.7

18.4

11.2

8.8

8.6

8.2

5.57.7

motor vehicle

consumer

business

(construction)

medical

academic

aerospace

govt.

others



Major RP

technique

SLS

3DPrinting

GPD

SLA

Ink jettechnique

Solidgroundcuring

FDM

LOM BPM





SELECTIVE LASER SINTERING (SLS) ▪ Production parts for unmanned aerial vehicles

▪ One piece fuel tanks

▪ Eliminates use of sub assemblies, adhesives or fasteners

▪ Health care & medical care application

▪ Investment casting process

▪ Gasket & facemask prototype

Industries where applied

▪ Aerospace and military

▪ Automotives

▪ Direct digital manufacturing



Prototypemanufacturing

Pattern masters for

investment casting

Direct tooling forsand casting

Direct tooling for

injection molding

Direct tooling for

die casting

Artificial heart





STEREO LITHOGRAPHY (SLA) ▪ Direct digital applications

▪ Medical & health care

▪ Hardware

▪ Tooling & pattern

▪ Investment casting patterns

▪ Jigs & fixtures

Industries where applied ▪ Health care industries

▪ Automotive components & structures

▪ Military

▪

steel plants



Digital applicationSpring

prototype

Jigs and fixtures

Home hardware Military hardware Human hand





FUSED DEPOSITION MODELLING (FDM) ▪ Fit testing Functional testing,

▪ Rapid tooling patterns, Small detailed parts,

▪ Presentation models,

▪ Patient and food applications

▪ High heat applications

Industries where applied:

▪ Health care industries

▪ Train , rail & car equipment industry

▪ Gas & oil production pipelines

▪ Pharmaceutical industry



Presentation

model

Gas pipeline

prototype

Fit & functional

testing

Building

prototypeSpinal cordprototype Statue

SLS SLA FDM



SLS SLA FDM

ADVANTAGES •Manufacturing of complex geometries

• High mechanical andthermal resistance.

•Rapid delivery time•Rubber like flexible

parts can be made usingelastomer Somos 201

•Low density complexinvestment casting

•Suitable for seals,

gaskets & hightemperature app

•High dimensionalaccuracy

•Greatest accuracywith an excellent

surface finish.•Suitable for making

master models forvacuum casting

process

• Parts can be bead

blasted, painted,textured finished,

electroplated

•Office-friendly and quiet

•FDM is fast for smallparts

•Strong and rigid parts

makes them suitable fortesting

•Dimensional stability is akey advantage

•At times products can bedirectly used as finished

product parts•High level of finish can be

achieved

DIS-ADVANTAGS

•SLS parts have littlerough & porous surface

finish

•Surface finish is not asgood and sharp asproduced by SLA

• Parts are sensitive toheat, moisture and

chemicals

•Not recommended forhigh humidity or

temperature

• Have a ribbedappearance because of

plastic is extruded in

horizontal layers• could be a slower process

for very large parts

MATERIALUSED

• Plastic, metal andelastomeric powders

with CO2 emission

•Photopolymer resinwith UV as emission

laser

•Solid (Filaments),thermoplastics &

elastomers and eutectoids

LIMITATIONS 700 x 380 x 580mm3 508x 508x600mm 203 x 203 x 305mm





Focused on meeting the needs of customers whilemaintaining high standards of quality andcontrolling the overall costs involved

Why is agile manufacturing an effectivestrategy?

Consumer’s love for gratification. Consumer’s love for choice. Consumers are fickle.



o The goal of agile production manufacturing is tooffer customized products at close to the price andspeed of mass-production.

o EXAMPLE….

Earlier there used to be Ford’s one-size fits-allautomobiles.



LEAN MANUFACTURING AGILE MANUFACTURING

Leanness is eliminating ‘wastes’ Eliminating wastes as well as

exploiting opportunities beingflexible and nimble

Cost is the market winner for leanmanufacturing

service levels and responsivenessfor Agile manufacturing.

Mass production as per orderplaced

Customer oriented production



Agile manufacturers are increasingly usingsophisticated CAD/CAM systems.

In addition, some manufacturers are turning tovirtual reality to test their design concepts.

ExampleCaterpillar Inc., for instances using virtual reality totest drive huge earthmoving machines before theyare built



The Product:▪ Conceptual validation: Esthetical, geometrical or

dimensional▪

Functional validation▪ Mechanical, thermal or any physical solicitation

validation▪ Finished machining validation

The Realization mode:▪ Tooling validation▪ Process validation▪ Fabrication cadence validation



Improve reactivity with respect to marketfluctuations

Help creativity and development of new concepts indesign

Simplify communication between customer and

supplier

Focused on configurability, modularity &upgradability of products and long-term satisfaction



Anticipate fabrication, maintenance, control orconditioning problems

Make rapid tests on the product to verify some of itscharacteristics (ergonomic, aerodynamic . .)

Form a part which will be used as a pattern in order

to make a tooling in a very short time.

To address the customers' real needs they must sellsolutions and not products.



Example: The great range, options and degree of customization offered by Dell computers havemade it the current market leader.

Honda’s new range of bikes come with an electronickey containing information that changes theperformance of the machines according to therider’s choice.



Liberalization → increased foreign investments → rapid strides in the field of hi-technologymanufacturing of electronic products.

Problem with electronics manufacturing is the“Constant change in technology to suit the trends and

customer requirements.”



OLD NEW

Product driven Customer driven

High product variety is bad High product variety is good

Product replacement Product upgrading

Functional orientation Product orientation

Economies of sale Economies of time

Dedicated equipments and jobs Agile equipments and jobsSingle enterprise Network enterprise

Information dynasties Open “seamless” information

Top-down management Vision-driven



SLS had the advantage to process wide range of material

While Agile integrates an organization's people and

technologies through innovative management

RP is an area in which agile plays a key role inprocesses such as SLS,SLA& FDM

Customers changing requirements are the demand while “Agile + RP“ is the only supply satisfying them.



Mechanisms in Selective Laser Sintering and Selective LaserMelting, Prof. Dr. Ir. J.P. Kruth, Ir. P. Mercelis, et al., Dept. of Metallurgy and Materials Engineering, Reviewed, accepted

August 4, 2004 (Pg.44-48). A Study of the STEREO LITHOGRAPHY Process, Deborah M.

Cottrill, Univ. of Wisconsin–Platteville, (Pg.1-6). PROCESSING and CHARACTERISATION of RAPID

PROTOTYPING by Deniz Uzunsoy, Univ. of Birmingham, June

2003, (Pg.27-34). Rapid prototyping : principles and applications by Rafiq

Noorani Journal of Materials Processing Technology 194 (2007) 81–88

RAPID PROTOTYPING PROCESS SELECTION using graph

theory and matrix approach by R. Venkata Raoa,, K.K.

Padmanabhanh i i i l

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CUTTING EDGE TECHNOLOGIES IN MANUFACTURING