Design for Advanced Manufacturing Technologies, and Processes

Title Page
Copyright Page
Contents
Contributors
Preface
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