Topic 4 - pt.3

Question 1

additive techniques

Answer 1

• paper-based rapid prototyping (PRP): layers of paper cut & glued = 3D shape
• laminated object manufacture (LOM): layers of material cut & glued = 3D shape
• stereolithography: solidification of powder using 3D printing

Question 2

subtractive techniques

Answer 2

• cutting: laser, saws, drilling
• machining: milling machine
• turning: metal or wood lathe
• abrading: sanding, filing, grinding

Question 3

shaping techniques

Answer 3

• injection moulding
• thermoforming
• strip heater to heat and bend acrylic
• casting: sand casting, die casting
• knitting
• weaving
• compression moulding

Question 4

C&C manufacturing

Answer 4

• computer numeric control
• instructions sent for x, y, z from CAD to printer –> draws layers stacked

Question 5

craft production

Answer 5

• makes single unique product by hand
• adv: locally based so clients can talk directly to manufacture, can sell for higher price
• disadv: labour intensive, skills required, slow production, high cost

Question 6

mechanized production

Answer 6

• volume production processes involving machines controlled by humans
• adv: less labour intensive

Question 7

automated production

Answer 7

• volume production processes, machines controlled by computers
• faster way of mass-producing
• automated systems can make complex decisions beyond human capacity
• quicker decision making than humans
• people tend to find routine jobs boring & can’t maintain quality like computers

Question 8

assembly line production

Answer 8

• volume production process
• products and components moved continuously along a conveyor –> components added as product goes from one workplace to another

Question 9

mass production

Answer 9

• large amounts of standardized products
• allows high rates of production per worker

Question 10

design for manufacture (DfM)

Answer 10

• products designed to be easily and efficiently manufactured to have minimal impact on env.
  1. design for material: chosen mat. can impact env.
  2. design for process: using a specific manufacturing process to have minimal waste
  3. design for assembly
  4: design for disassembly: when it becomes obsolete it can easily & economically be taken apart

Question 11

mass customization

Answer 11

• sophisticated CIM system: manufactures products for individual customers

Question 12

robot work envelope

Answer 12

• clearance and reach
• distance determined by robot’s arm and design of its axis
• gantry robots defy traditional constraints

Question 13

load capacity

Answer 13

• weight a robot can manipulate

Question 14

single-task robots

Answer 14

• adv: reduces chance of error
• disadv: expensive, long processes as little can be done

Question 15

multi-task robots

Answer 15

• adv: manufacture sped up & more efficient
• disadv: increases chance of error

Question 16

teams of robots

Answer 16

• adv: increased efficiency, one can hold parts while other performs tasks

Question 17

machine to machine (M2M)

Answer 17

• wired and wireless communication between similar devices
• e.g. vending machine (message sent to distributor when food low)

Question 18

first generation robots

Answer 18

• simple mechanical arm w/ ability to make precise motions at high speed
• needs constant supervision by humans

Question 19

second generation robots

Answer 19

• equipped with sensors that provide info about their surroundings
• doesn’t need constant human supervision
• they can synchronize with each other

Question 20

shaping: compression moulding

Answer 20

• most important process for manufacturing thermosets
• material placed between two halves and pressed
• slightly heated to from cross-link bonds
• low waste & low set up cost

Question 21

third generation robots

Answer 21

• autonomous = can control itself
• can operate largely without supervision
• when autonomous robots don’t perform efficiently –> group of insect robots can be used by robot by itself doesn’t have AI but group as a whole has intelligence

Question 22

laser cutting

Answer 22

• focused laser beam melts/burns/vaporizes material
• industrial laser cutters cut flat-sheet material

Question 23

shaping: blow moulding

Answer 23

• air injected into material to shape it
• suited for high and low production scales

Question 24

shaping: rotational moulding:

Answer 24

• moulds filled with thermoplastics powder
• mould is rotated while particles heated
• good for rigid, tough, flexible plastic
• only hallow shapes can be produced

Question 25

shaping: vacuum forming / thermoforming

Answer 25

• material heated then mould pushed against
• vacuum pumps out all air from beneath
• may have high waste

Question 26

shaping: extrusion

Answer 26

• powder heated, forced through a die, extruded, and cut
• best way to make long products

Question 27

shaping: sand casting

Answer 27

• pattern made, parts placed on base board, sand packed around it – pattern removed & halves aligned so metal can be poured
• easy and low cost, can require lots of finishing

Question 28

shaping: high pressure die casting

Answer 28

• molten metal is forced, with pressure, into a sealed mould cavity & pins push component out of die
• suitable for low-melting point metals, high detail achievable –> good for complex shapes
• fast but expensive & only suitable for high-volume production

Question 29

wood laminating

Answer 29

• adhesive applied to each veneer, stacked, and clamped into position in a die
• suitable for one-off, batch, and mass production
• strong and lightweight components