The goal of fabricating functional prototypes quickly is hindered by a mismatch of material properties between production materials and those used in rapid prototyping (RP) machines, such as stereolithography. Even when rapid tooling (RT) technologies are utilized for injection molded parts, differences in mold materials cause differences in molded part properties. To compensate for these material and process differences, a design for manufacturing (DFM) method is introduced, called geometric tailoring. The idea is to modify dimensions of prototype parts to match key characteristics of production parts, such as stress and deflection behaviors. For RP parts, the geometric tailoring DFM method integrates two sub-problems, one for achieving functional requirements by matching part behaviors, and one for RP process planning to incorporate manufacturing capabilities and limitations. For parts fabricated by RT, an additional sub-problem is integrated, namely injection molding process planning. Problem decomposition is critical due to the coupled nature of the sub-problems. A problem decomposition and solution procedure is presented. The geometric tailoring method is shown to enable the matching of prototype to production part behaviors, while improving manufacturability.
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July 2004
Technical Papers
Geometric Tailoring: A Design for Manufacturing Method for Rapid Prototyping and Rapid Tooling
Shiva Sambu,
Shiva Sambu
The George W. Woodruff School of Mechanical Engineering, Georgia Institute of Technology, Atlanta, GA 30332-0405
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Yong Chen,
Yong Chen
The George W. Woodruff School of Mechanical Engineering, Georgia Institute of Technology, Atlanta, GA 30332-0405
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David W. Rosen, Professor
David W. Rosen, Professor
The George W. Woodruff School of Mechanical Engineering, Georgia Institute of Technology, Atlanta, GA 30332-0405
Search for other works by this author on:
Shiva Sambu
The George W. Woodruff School of Mechanical Engineering, Georgia Institute of Technology, Atlanta, GA 30332-0405
Yong Chen
The George W. Woodruff School of Mechanical Engineering, Georgia Institute of Technology, Atlanta, GA 30332-0405
David W. Rosen, Professor
The George W. Woodruff School of Mechanical Engineering, Georgia Institute of Technology, Atlanta, GA 30332-0405
Contributed by the Design Theory and Methodology Committee for publication in the JOURNAL OF MECHANICAL DESIGN. Manuscript received May 2002; rev. Nov. 2003. Associate Editor: L. C. Schmidt.
J. Mech. Des. Jul 2004, 126(4): 571-580 (10 pages)
Published Online: August 12, 2004
Article history
Received:
May 1, 2002
Revised:
November 1, 2003
Online:
August 12, 2004
Citation
Sambu, S., Chen, Y., and Rosen, D. W. (August 12, 2004). "Geometric Tailoring: A Design for Manufacturing Method for Rapid Prototyping and Rapid Tooling ." ASME. J. Mech. Des. July 2004; 126(4): 571–580. https://doi.org/10.1115/1.1758250
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