MANUFACTURING SYSTEMS

MVS 311

Lecturer: Dr R Meeser

This module follows on the manufacturing knowledge

gained in the first year in Graphical Communication
(MGC 110), and second year in Manufacturing and
Design (MOW 217)
 GRAPHICAL COMMUNICATION
(MGC 110) – MANUFACTURING

General introduction to manufacturing processes,

Metal casting processes, Sheet metal working,
Machining operations and machine tools.
 MANUFACTURING &
DESIGN (MOW 217)

Manufacturing and Design (MOW217) builds on the basic

MGC110 knowledge by exposing students to
• Selection (through calculation / catalogue process) of a
wide range of mechanical bought-out items. Where
applicable, implementation of these bought-out items will
also be addressed.
• An in-depth study of Geometric Dimensioning and
Tolerancing (GD&T), and
• A South African perspective of selected manufacturing
processes
©2013 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 5/e
 OVERVIEW OF MVS 311:
STUDY TOPICS

1 Rapid Prototyping and Additive Manufacturing Chapter 29

2 Processing of integrated circuits Chapter 30
3 Electronics assembly and packaging Chapter 31
4 Microfabrication technologies Chapter 32
5 Nanofabrication technologies Chapter 33
6 Automated technologies for manufacturing systems Chapter 34
7 Integrated manufacturing systems Chapter 35
8 Process planning and production control Chapter 36
9 Quality control and inspection Chapter 37
 OVERVIEW OF MVS 311:
CONTACT TIME

Lecture slides and other study material: MVS 311 Click-UP page

Day Time Venue Type

Monday 09:30 – 10:20 Eng III – 5 Lectures

Tuesday 09:30 – 10:20 Eng III – 2
Wednesday 12:30 – 13:20 Eng III – 2
Thursday 11:30 – 14:20 Eng III – 2 Tutorial
 OVERVIEW OF MVS 311:
RULES OF ASSESSMENT

Pass requirements: final mark of at least 50%.

Calculation of the final mark:
Semester mark (40% exam entrance): 50%
Examination mark (40 sub-minimum): 50%
Calculation of the semester mark
1st Semester tests: 25%
2nd Semester Test 25%
Assignment: 30%
Class tests/assessments: 20%
Semester mark: 100%
(Closed book tests/examination)
 OVERVIEW OF MVS 311
SEMESTER ASSIGNMENT

Assignment topic:
The group project for 2025 is for the students to write a proposal for a production
facility that is to produce additive manufacturing machines (3D printers only form
a part of this) in large quantities.

Duration: 17 February 2025 – 23 May 2025 (hand in date)

Further details are uploaded onto clickUp, under the tab “Group
Assignment”
 SPECIAL PROCESSING AND
ASSEMBLY TECHNOLOGIES

Rapid Prototyping and Additive Manufacturing (mid-1980s)

Processing of Integrated Circuits 1960s
Electronics Assembly and Packaging
Microfabrication Technologies (follow soon after IC processing)
Nanofabrication Technologies (1990)

©2013 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 5/e
 RAPID PROTOTYPING AND
ADDITIVE MANUFACTURING
Development of RP and AM is based on several enabling
technologies
Beginnings of RP in the mid-1980s when similar patents were
filed on “constructing a 3-D object by adding a sequence of layers, one on
top of the previous”
Patent by Charles Hull resulted in commercial development of
stereolithography (SL) and the formation of the company 3D Systems, Inc.
Several additional patents followed in 1986
Solid Ground Curing (SGC) – exposed photopolymers through a
physical mask
Selective Laser Sintering (SLS) – used lasers to sinter or melt
powder layers
Laminated Object Manufacturing (LOM) – cut paper sheets in the
part building procedure

©2013 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 5/e
 RAPID PROTOTYPING AND
ADDITIVE MANUFACTURING
l1986 (cont) 3 start-up companies were formed, of which the
company DTM commercialised Selective Laser Sintering (SLS).
lFused Deposit Modeling (FDM) was patented in 1989 and

Stratasys Company was formed to commercialise the technology

l1989 – MIT researchers patented “3-D Printing”, using ink-jets to

deposit droplets of binder onto layers of powdered material.

l1994 – similar approach based on ink-jet technology was

developed to deposit the material itself to form layers rather than a

binder on powder
lThis summarises the majority of RP and AM technologies used

today
lEven SGC and LOM are used in altered forms

©2013 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 5/e
 RAPID PROTOTYPING AND
ADDITIVE MANUFACTURING

1.Fundamentals of Rapid Prototyping and Additive

Manufacturing
2.Additive Manufacturing Processes
3.Cycle Time and Cost Analysis
4.Additive Manufacturing Applications

©2013 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 5/e
 Rapid Prototyping (RP) and
Additive Manufacturing (AM)
Family of fabrication processes to make engineering
prototypes or production parts in minimum lead time
based on a CAD model of the item
Traditional method is machining and can require
significant lead-times – weeks, depending on part
complexity and difficulty in ordering materials
RP/AM allows a part to be made in hours or days,
given that a computer model of the part has been
generated on a CAD system
One might say that RP is a subset of AM when the
purpose is to make a prototype

©2013 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 5/e
 Why is Rapid Prototyping
Important?
Product designers want to have a physical model of a
new part or product design rather than just a computer
model or line drawing
Creating a prototype is an integral step in design
A virtual prototype (a CAD model of the part) may
not be sufficient for the designer to visualize the part
adequately
Using RP to make the prototype, the designer can
see and feel the part and assess its merits and
shortcomings

©2013 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 5/e
 Available Rapid Prototyping
Technologies

1.Material removal RP - machining, using a dedicated

CNC machine that is available to the design department
on short notice
Starting material is often wax
The CNC machines are often small - called desktop
machining
2.Material addition RP - adds layers of material one at a
time to build the solid part from bottom to top

©2013 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 5/e
 Advantages of Material Addition
RP Technologies

Speed of part delivery

Avoidance of the CNC part programming task,
because the CAD model is the part program in material
addition RP
Complexity of part geometry is not an issue in material
addition RP

©2013 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 5/e
 Steps to Prepare Control
Instructions (i.e., part program)

1.Geometric modeling - design the component on a

CAD system to define its enclosed volume
2.Tessellation of the geometric model - CAD model is
converted into a computerized format that approximates
its surfaces by facets (triangles or polygons)
3.Slicing of the model into layers - computerized model
is sliced into closely-spaced parallel horizontal layers

©2013 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 5/e
1. 3D model 2. Tessellation
 Solid Model to Layers

(a) Conversion of a solid model of an object into layers (b)

only one layer is shown

©2013 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 5/e
 Starting Materials in Material
Addition RP

1.Liquid polymers that are cured layer by layer into solid

polymers
2.Powders that are aggregated and bonded layer by
layer
3.Molten materials that are solidified layer by layer
4.Solid sheets that are laminated to create the solid part

©2013 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 5/e
 Layer-Forming Processes

Lasers
Printing heads that operate using ink-jet technology
Extruder heads
Other processes:
Electron beams
Cutting knives
UV light systems

©2013 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 5/e
 Three Basic Channel Modes

(a) Moving point or moving spot, (b) moving line across the
entire layer in one translational motion, and (c) layer mode -
entire layer is created at the same time

©2013 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 5/e
 Additive Manufacturing
Processes

1.Liquid-based: Stereolithography (SL) and mask

projection stereolithography (MPSL)
2.Powder-based: Selective laser sintering (SLS) and
three-dimensional printing (3DP)
3.Molten material: Fused deposition modeling (FDM)
and droplet deposition manufacturing (DDM)
4.Solid-based: Laminated object manufacturing (LOM)

See Table 29.1

©2013 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 5/e
 Liquid-Based AM System:
Stereolithography (SL)

RP process for fabricating a solid plastic part out of a

photosensitive liquid polymer using a directed laser
beam to solidify the polymer
Part fabrication is accomplished as a series of layers -
each layer is added onto the previous layer to gradually
build the 3-D geometry
The first addition RP technology - introduced 1988 by
3D Systems Inc. based on work of Charles Hull

©2013 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 5/e
 Stereolithography

(1) At start of the process, in which the initial layer is added to

the platform; and (2) after several layers have been added so
that the part geometry gradually takes form

©2013 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 5/e
 Facts about Stereolithography

Typical layer thickness is 0.05 mm to 0.150 mm (0.002

in to 0.006 in) thick
Thinner layers provide better resolution and more
intricate shapes, but processing time is longer
Typical liquid photopolymers include acrylic and epoxy
Polymerization occurs on exposure to UV light
produced by laser scanning beam
Scanning speeds ~ 500 to 2500 mm/s

©2013 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 5/e
https://www.youtube.com/watch?v=yW4EbCWaJHE
Example of a prototype thermal monocular
body that was made using stereolithography
Installed:
But did it work?
 Example of overhanging
features
If the lower half of the handle and the lower handle bar were
eliminated, the upper portion of the handle would be unsupported
during the “bottom-up” manufacturing process

©2013 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 5/e
 Liquid-Based AM System:
Mask Projection
Stereolithography (MPSL)
Conventional stereolithography uses a single moving
laser beam to cure the polymer
MPSL exposes the entire layer using a UV light source
through a dynamic mask instead of a scanning laser
beam
Dynamic mask is digitally altered for each layer
using a digital micromirror device consisting of
several hundred thousand microscopic mirrors
Exposure and curing process in MPSL is therefore
shorter than in conventional SL

©2013 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 5/e
 0.016 mm
©2013 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 5/e
 Mask Projection
Stereolithography (MPSL)

Texas Instruments DLP

Digital Micomirror Device
©2013 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 5/e
Digital Micro-mirror Device
 Powder-Based AM System:
Selective Laser Sintering (SLS)
Moving laser beam sinters heat-fusible
powders in areas corresponding to the CAD
geometry model one layer at a time to build
the solid part
After each layer is completed, a new
layer of loose powders is spread across
the surface
Layer by layer, the powders are gradually
bonded by the laser beam into a 3-D solid
geometry
In areas not sintered, the powders are
loose and can be poured out of completed New layer of loose powders
part is spread and leveled using
a counter-rotating roller

©2013 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 5/e
 Powder-Based AM System:
Selective Laser Sintering (SLS)
Layer thickness is 0.075 to 0.5 mm
The SLS process is usually accomplished in an enclosure that
is filled with nitrogen to minimize the degradation of powders
that might be susceptible to oxidation (e.g., metals)
SLS was developed by Carl Dekard at the University of Texas
(Austin) in the mid 1980s as an alternative to Stereolithography
(patented in 1989)
SLS machines were marketed by the company DTM formed by
Dekard and two partners
DTM merged with 3D Systems Inc in 2001

©2013 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 5/e
 Powder-Based AM System:
Selective Laser Sintering (SLS)
SLS is a more versatile process than Stereolithography in
terms of possible work materials
SLS materials include polymers, metals and ceramics
SLS is a Powder Bed Fusion (PBF) process.
Other PBF systems differ from SLS in the following ways:
lHeating or fusion techniques

lMethods of handling the powders

lMechanisms by which the powders are bonded into solid

objects
lLine-wise and layer-wise processes are also used as

opposed to the point-wise process in SLS

©2013 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 5/e
 Powder-Based AM System:
Three Dimensional Printing
(3DP)
Part is built using an ink-jet printer to eject adhesive
bonding material onto successive layers of powders
Binder is deposited in areas corresponding to the cross
sections of part, as determined by slicing the CAD
geometric model into layers
The binder holds the powders together to form the
solid part, while the unbonded powders remain loose to
be removed later
To strengthen the part, a sintering step can be applied
to bond the individual powders

©2013 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 5/e
 Powder-Based AM System:
Three Dimensional Printing
(3DP)
(1) Powder layer is deposited, (2) ink-jet printing of areas
that will become the part, and (3) piston is lowered for next
layer

©2013 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 5/e
 Powder-Based AM System:
Three Dimensional Printing
(3DP)
Starting materials in 3DP are
lPowders of ceramic, metal or cermet*

lBinders that are polymeric or colloidal silica** or silicon carbide

*A cermet is a composite material composed of ceramic (cer) and

metallic (met) materials. A cermet is ideally designed to have the
optimal properties of both a ceramic, such as high temperature
resistance and hardness, and those of a metal, such as the ability
to undergo plastic deformation

**Colloidal silica is industrially manufactured Silicon Oxide and is

composed of polymeric silicates (polymeric / polymer - large
molecule composed of many repeated subunits)

©2013 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 5/e
 Powder-Based AM System:
Three Dimensional Printing
(3DP)
Typical layer thickness: 0.1 – 0.2 mm
The ink-jet printing head moves
across the layer at about 1.5m/s
Ejection of liquid binder is determined
during the sweep by raster scanning
2 second cycle time per layer
3DP machines can operate at a rate
of 2 to 4 layers per minute Raster scan

©2013 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 5/e
Selective Laser Sintering
https://www.youtube.com/watch?v=9E5MfBAV_tA
SLS
https://www.youtube.com/watch?v=bgQvqVq-SQU
 Molten Material AM Systems:
Fused Deposition Modeling
(FDM)
RP process in which a long filament of wax and / or
thermoplastic polymer is extruded onto existing part
surface from a workhead to complete each new layer
Workhead is controlled in x-y plane during each layer
and then moves up by a distance equal to one layer in
the z-direction
Extrudate is solidified and cold welded to the cooler
part surface in about 0.1 s
Part is fabricated layer-by-layer from the base up
Typical layer thickness is 0.25 to 0.33mm (can be
set to a minimum of 0.076mm)
©2013 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 5/e
Ring template made from a wax 3-D print, and
then it is set in a mould material, the wax is
melted out and the precious metal cast in that
volume. Details/features as small as 0.3mm can
be achieved using this process
 Molten Material AM Systems:
Fused Deposition Modeling
(FDM)
Disadvantages of FDM:
relative slow speed because deposited material is
applied in a moving-point channel mode
difficult to form sharp corners because of circular
nozzle orifice
FDM developed by Stratasys Inc.,
sold their first machine in 1990
today there are more FDM machines throughout the
world than any other AM machine

©2013 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 5/e
 Collection of Parts Made by
Fused Deposition Modeling

(Courtesy of
George E. Kane
Manufacturing
Technology
Laboratory,
Lehigh University)

©2013 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 5/e
FDM Machine
(Courtesy of
George E. Kane
Manufacturing
Technology
Laboratory,
Lehigh University)

©2013 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 5/e
https://www.youtube.com/watch?v=ik39_sv-wgQ
https://www.youtube.com/watch?v=WHO6G67GJbM
 Molten Material Systems: Droplet
Deposition Manufacturing (DDM)

DDM is also known as Balistic-Particle Manufacturing

Starting material is melted and small droplets are shot
by a nozzle onto previously formed layer
Droplets cold weld to surface to form a new layer
Deposition for each layer controlled by a moving x-y
nozzle whose path is based on a cross section of a
CAD geometric model that is sliced into layers
Work materials include wax and thermoplastics

©2013 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 5/e
https://www.youtube.com/watch?v=Pjqysyy1ySs
LDT: https://www.youtube.com/watch?v=d2foaRi4nxM
 Solid Sheet-Based AM Systems:
Laminated Object Manufacturing
(LOM)
Solid physical model made by stacking layers of sheet
stock, each an outline of the cross-sectional shape of a
CAD model that is sliced into layers
Starting sheet stock includes paper, plastic,
cellulose, metals, or fiber-reinforced materials
Sheet usually supplied with adhesive backing as
rolls that are spooled between two reels
After cutting, excess material in the layer remains in
place to support the part during building

©2013 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 5/e
 Solid Sheet-Based AM Systems:
Laminated Object Manufacturing
(LOM)

©2013 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 5/e
 Solid Sheet-Based AM Systems:
Laminated Object Manufacturing
(LOM)
LOM part sizes – relatively large among AM processes
Work volumes up to 800 mm X 500 mm X 550 mm
More common work volumes 380 mm X 250 mm X 350 mm
Helisys, Inc. was the original company offering LOM systems
The Helisys machine
Processed paper backed with adhesive
Sequence: the most recently added sheet was bonded to the existing structure
before cutting the outline in that layer
Heated roller was used to melt the thermoplastic adhesive in the bonding
operation
Modifications in LOM introduced by other companies
Cutting blade in stead of laser
Polymeric sheet stock rather than paper
Process sequence – cut the layer outline before bonding (objects with internal
features)
©2013 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 5/e
 Electron beam welding
https://www.youtube.com/watch?v=zX9tvdTEAEo
 RP Cycle Time Analysis

Time Ti to complete a single layer in processes that use

a moving-spot channel mode
Ai
Ti   Tr
vD
where Ai = area of layer i
V = speed of moving spot
D = diameter of moving spot (assumed circular)
Tr = repositioning time between layers

©2013 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 5/e
 RP Cycle Time Analysis

Time Ti to complete a single layer in processes that use

a moving-line channel mode
Ti  v s Ls  Tr
where vs = velocity of moving line
Ls = length of sweep across layer

Time Ti to complete a single layer in processes that use

a layer channel mode
Ti = Tex + Tr
Where Tex = exposure time for one layer
©2013 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 5/e
 RP Cycle Time Analysis

Total cycle time Tc to build the part is the sum of the

individual layer times Ti plus the time to set up the
machine nl
Tc  Tsu  Ti
i 1

where Tsu = machine setup time

nl = number of layers to approximate the part
nl = part height divided by layer thickness

©2013 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 5/e
 RP Cost Analysis

Cost per piece Cpc by any of the RP processes includes

material, labor, and machine operating cost
Cpc = Cm + (CLUL + Ceq)Tc + CLTpp
where Cm = material cost per piece
CL = labor cost per hour
UL = labor utilization factor (machine is automatic)
Ceq = equipment cost per hour
Tc = cycle time per piece
Tpp = post-processing time per part

©2013 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 5/e
 Additive Manufacturing
Applications

Applications of rapid prototyping can be classified into

four categories:
1.Design
2.Engineering analysis and planning
3.Tooling
4.Parts production

©2013 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 5/e
 Design Applications

Designers are able to confirm their design by building a

real physical model in minimum time using RP
Design benefits of RP:
Reduced lead times to produce prototypes
Improved ability to visualize part geometry
Early detection of design errors
Increased capability to compute mass properties

©2013 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 5/e
 Engineering Analysis and
Planning
Existence of part allows certain engineering analysis and planning
activities to be accomplished that would be more difficult without
the physical entity
Comparison of different shapes and styles to determine aesthetic
appeal
Analysis of fluid flow through different orifice designs in valves
Wind tunnel testing of different streamline shapes
Stress analysis of physical model
Fabrication of pre-production parts for process planning and tool
design
Combining medical imaging technologies with RP to create models
for doctors
In planning surgical procedures, or
Fabricating prostheses or implants
©2013 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 5/e
 Engineering Analysis and
Planning
Fabricating prostheses or implants:
E-nable – a volunteer organisation that uses 3-D printing to create
inexpensive prosthetic arms

©2013 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 5/e
 Tooling Applications

Called rapid tool making (RTM) when RP is used to

fabricate production tooling
Two approaches for tool-making:
1.Indirect RTM method
2.Direct RTM method

©2013 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 5/e
https://www.youtube.com/watch?v=3CVEUVl61G8
 Indirect RTM Method

Pattern is created by RP and the pattern is used to

fabricate the tool
Examples:
Patterns for sand casting and investment casting
Electrodes for EDM

©2013 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 5/e
 Direct RTM Method

RP is used to make the tool itself

Example:
3DP to create a die of metal powders followed by
sintering and infiltration to complete the die

©2013 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 5/e
EDM: https://www.youtube.com/watch?v=2W4xZYRkWGo
 Parts Production

Small batches of plastic parts that could not be

economically molded by injection molding because of
the high mold cost
Parts with intricate internal geometries that could not
be made using conventional technologies without
assembly
Spare parts (make as needed rather than inventory)
One-of-a-kind parts such as bone replacements that
must be made to correct size for each user

©2013 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 5/e
 Problems with Rapid Prototyping

Part accuracy:
Staircase appearance for a sloping part surface
due to layering
Shrinkage and distortion of RP parts
Limited variety of materials in RP
Mechanical performance of the fabricated parts is
limited by the materials that must be used in the RP
process

©2013 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 5/e