The document discusses advanced manufacturing choices and processes. It introduces different types of energy that can be used for manufacturing including mechanical, electrical, heat, and chemical energy. Students will learn to decide which manufacturing process to use based on a product's specifications and design. They will learn when to use different mechanical and lithography-based machining methods as well as when to employ top-down vs. bottom-up manufacturing. The document provides an overview of topics that will be covered in the course, which include various manufacturing processes, rapid prototyping, and how to match processes to product requirements.

1. ADVANCED
MANUFACTURING
CHOICES

2. Advanced Manufacturing Choices
 Manufacturing processes can be organized by considering the type
of energy required to shape the work-piece. In this course, sources
of energy considered for manufacturing are:
 Mechanical energy such as in cutting and shaping
 Electrical energy
 Heat energy such as in laser cutting,
 Chemical energy such as in electro chemical machining.
 Categorizing is often not that simple (e.g., chemical and thermal). It
is easier to categorize in the case of subtractive than in the case of
additive manufacturing.
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3. Advanced Manufacturing Choices
 Students, guided by product specifications and a design will be
able to decide:
 1)When to apply mechanical machining vs. lithography based
machining,
 2) What type of mechanical machining and what type of lithography
based machining to apply,
 3)When to employ bottom-up vs. top-down manufacturing,
 4)When to choose serial, batch or continuous manufacturing and
 5)What rapid prototyping method to select.
 A logical decision tree will be presented to sort out the
machining options.
 Examples will include a variety of products ranging in size from
nanometers to centimeters.
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4. Advanced Manufacturing
Choices
 The size of things
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5. Advanced Manufacturing Choices
 Syllabus:Topics
1. Serial, batch and continuous manufacturing processes.
2. Relative tolerances vs. absolute machining tolerances.
3. Principles of manufacturing processes I. Mechanical energy:
e.g., Cutting, Shaping, Forging, Ultrasonic Machining,
Sputtering.
4. Principles of manufacturing processes II. Electrical energy:
e.g., Electron Discharge Machining (EDM)
5. Principles of manufacturing processes III. Heat energy: e.g. ,
Laser machining, plastic molding.
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6. Advanced Manufacturing Choices
6. Principles of manufacturing processes IV. Chemical energy:
Electrochemical Machining (ECM), Chemical Machining
7. Next generation lithography tools,
8. Nanomachining tools.
9. Top-down vs. bottom-up machining.
10. Rapid prototyping, layered manufacturing.
11. Matching manufacturing processes to product specification and design.
12. Manufacturing process decision tree.
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7. Class 1
 Definition of manufacturing
 Serial, batch and continuous manufacturing
processes.
 Relative tolerances vs. absolute machining
tolerances.
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8. Definition of
Manufacturing
 Manufacturing is the use of machines, tools and labor to
make things for use or sale.The term may refer to a
range of human activity, from handicraft to high tech,
but is most commonly applied to industrial production,
in which raw materials are transformed into finished
goods on a large scale. Such finished goods may be used
for manufacturing other, more complex products, such
as household appliances or automobiles, or sold to
wholesalers, who in turn sell them to retailers, who then
sell them to end users - the "consumers". Wikipedia
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9. Serial, batch and continuous
manufacturing processes.
 Single unit production or serial production
 The primary characteristic of batch production is
that a group of identical components are
completed at a workstation before they move to
the next one (e.g., IC fabrication).
 Continuous production is a method used to
manufacture, produce, or process materials
without interruption
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10. Serial, batch and continuous
manufacturing processes.
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11. Serial, batch and continuous
manufacturing processes.
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12. Relative tolerances vs. absolute
machining tolerances.
 A dimension is a numerical value
expressed in appropriate units of
measure and used to define size,
location, orientation, form or other
geometric characteristics of a part.
 A tolerance is the acceptable variation of
feature from the specified dimension
 Relative tolerance: tolerance on
dimension over dimension
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Dimension with
Limit Tolerance
Dimension with
Plus-Minus Tolerance

13. Relative tolerances vs. absolute
machining tolerances.
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14. Relative tolerances vs.
absolute machining tolerances.
 Lithography (e.g. Si-
micromachining) is excellent
for small absolute tolerances
 For relative tolerances, ultra-
fine diamond milling is
better
 In some cases we might want
to keep our micromachine
somewhat larger to optimize
relative tolerances
10 km
1 km
100 m
10 m
1 m
10 cm
1 cm
1 mm
100 µm
10 µm
1 µm
0.1 µm
0.01 µm
1 nm
1 Å
Absolute size
Absolute tolerance
Precision Machining Application Domain
Linear dimension
Linear dimension
0.01 %
Relative Tolerance
City
House
Arm
Optic
al
fiber
Virus
Atom
Relative tolerances for building
a house and a lithography based
micromachine
Bacteria
100 m
1 m
1 cm
100 µm
1 µm
0.01 µm
Precision M achining
1%100 %10 % 0.1 % 0.0001 %0.01 %
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15. Relative tolerances vs.
absolute machining tolerances.
 “The total amount by
which a given dimension
may vary, or the
difference between the
limits” - ANSIY14.5M-
1982(R1988) Standard
[R1.4]
 Nominal tolerances for
steel (see figure)
 Tighter tolerances =>
increase cost $
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