POOFF! There it is!Digital Manufacturing
University of Southern California
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d-fab (DRAFT)
A New Course on
Fabricator Science

The Science and Technology
of Digital Manufacturing

by Marshall Burns, Ph.D.
and collaborators TBD

Sections on this page:
   Outline

Copyright © 2004, Ennex Corporation. All rights reserved.
Background:

     This is a draft of a textbook for a course in fabricator science, the studies underlying the new technology of digital manufacturing. This book is a new edition of Automated Fabrication—Improving Productivity in Manufacturing, originally published by Prentice Hall in 1993, reorganized and with substantial new material. It is being prepared as the text for two courses in the Department of Industrial and Systems Engineering at the University of Southern California:

  • ISE 232L, Manufacturing Processes, undergraduate
  • ISE 511L, Computer-Aided Manufacturing, grad level
Note to students on January 11, 2005:

     The new book is undergoing some final preparations for you. When it is ready, the headings in the table of contents below will link directly to the respective chapters and sections. (“Ready” does not mean the book will be finished or complete. It means that the content will be sufficiently organized for you to use it productively. See Is This for You? for more information on the textbook for this course.) In the meantime, I’m making the first edition available to you to study from. At the present time, the table of contents below has an extra column on the right-hand side with links to the relevant sections of the first edition. You can also browse the table of contents of the entire first edition. There are two problems with the material you will find behind these links:

  • While the entire text of the first edition is there, most of the pictures and most of the tables have not been uploaded yet. So for most pictures and tables, you will see only a caption.
  • The first edition was published over ten years ago and a lot has changed since then. The old book is still valuable for conceptual content that explains the underlying principles of digital manufacturing, but detailed information on machines, materials, processes, and applications is outdated.

     The good news is that the old book is being provided to you for free. You will not have to sign up and pay for textbook access until the new book is ready. I hope to have it ready for you by next week.


Outline (DRAFT)

     The table below is interactive and can be expanded and collapsed to show or hide levels of detail. Click the numbers at the top of the table to change the level of detail shown.

     Do not trust the chapter and section numbers at this point. They are automatically generated by counting content and will change as content changes.

Table of Contents
Currently showing 3 levels of topic detail. Change to 1/ 2/ 4/ 5 levels.
TopicBased on
 undefined Candidate Titles
 undefined Organization of Image Files
 undefined Idea for New Structure
 undefined Generations of Digital Manufacturing Technology
 undefined  hLink('Sct'
 undefined  hLink('Sct'
 undefined Artificial Embryology
 undefined Industrial/Digital Relationship
 undefined DedicationAF
 undefined ForewordAF
 undefined PrefaceAF
 undefined AudienceAF
 undefined Organization of the BookAF
 undefined Units of MeasureAF
 undefined TerminologyAF
 undefined AcknowledgmentsAF
 undefined An Invitation to the ReaderAF
Groundwork
 1 Introduction to
Digital Manufacturing
AF 1
 1.1 What is Manufacturing
  What do we make?
  Elements of Manufacturing
  Making Objects
  Paradigms of Manufacturing
  Economic Role of Manufacturing
  The Manufacturing Market
 1.2 What is Digital
 1.3 Digital ManufacturingAF 1
  A New Paradigm
  Modern Tools
  Fabbers
  How Digital Manufacturing is Used
  Considerations
  Terminology
  What To Make
  The Digital Manufacturing MarketAF 1
  Markets
 2 A Brief History of Manufacturing
  The Pace of Change
 2.1 Natural Ways of Making Things
  Cosmogony: Creation of Matter
  Embryology: Growth of Living Organisms
  Natural Habitat Construction
  Self-Organization
 2.2 Ancient Human Crafting
  Subtractive Fabrication in Stone, Wood, and Bone
  Hybrid Fabrication: Pottery
  Formative Fabrication in Metals
  Additive Fabrication: Masonry
  Textiles: Spinning and Weaving
  Analog Formative Fabrication: Molding
  Analog Formative Fabrication: MoldingAF App. B
 2.3 Industrial Manufacturing
  Artificial Power
  Standardization of Parts
  Routinization of Process
  Automation
  Electronics
  Plastics
  Computer-Aided Design
 2.4 Digital Manufacturing
  Comparison with Computers
  A Vision of the Future
II Digital Manufacturing Today
 3 Digital DesignAF 6
 3.1 3-D Shape RepresentationData Formats
  3-D Data Formats
  Data Transfer
  Data Translators
  The StL Format
 3.2 3-D CADAF 6.1
  Guidelines for Choosing a 3-D CAD Program
  A Selected List of 3-D CAD Programs
 3.3 ScannersAF 6.2
  Levels of DigitizationAF 6.2
  The Elements of a 3-D Shape DigitizerAF 6.2
  Types of Matter SensorsAF 6.2
  Fabber Applications of 3-D Shape Digitization
 3.4 Mathematical DesignAF 6.3
 3.5 Related SoftwareAF 6.4
  Computer VisualizationAF 6.4
  Fabricator-Accessory Software
 3.6 Related Hardware
  3-D Displays
 4 Digital MaterialsAF 7
 4.1 An Introduction to Solid MaterialsAF 7.1
 4.2 Properties of Solid ObjectsAF 7.2
  Smart MaterialsAF 7.2
 4.3 A Partial Catalog of Properties of SolidsAF 7.3
  Inertial PropertiesAF 7.3
  Interaction PropertiesAF 7.3
  Properties Data for Common Solid MaterialsAF 7.3
 4.4 Materials for Additive FabricationAF 7.4
  Fabricated Millistructure at 3D Systems
  Curing Properties of Photopolymer Resins
  Properties Data for Commercial Fabricator Materials
  Safety Issues of Fabricator Materials
  Metals by Additive Processes
 5 Digital FabricationAF 2
  Table of Commercially Available Fabricators
 5.1 CNC MachiningAF 2.1
  A Few Examples of Milling Machines
  Lathes
  Wire EDM
 5.2 Pattern LaminationAF 2.4
  Bond-First Pattern Lamination: Helisys
  Shearing and Bending
 5.3 Continuous DepositionAF 2.3
  Robotically Guided Extrusion: Stratasys
 5.4 Droplet DepositionAF 2.3
  Droplet Deposition on Powder: Soligen
 5.5 Selective SinteringAF 2.3
  Selective Sintering: DTM
 5.6 Selective CuringAF 2.2
  Patent and Development History
  StereoLithography: 3D Systems
  Other Laser Curing
  Masked-Lamp Curing: Cubital
 5.7 Fabber Spec Tables
  Specification Tables on the Individual Machines
 6 Digital ProductsAF 4
  Uses and Users: What Are Fabbers Used For?
 6.1 Direct Fabber ManufacturingAF 4.1
  Production by Additive Fabricators
  Case Studies
 6.2 Models and PrototypesAF 4.2
  Iteration for Satisfaction and OptimizationAF 4.2
  Case Studies
 6.3 Replication ToolingAF 4.3
  Direct Generation of MoldsAF 4.3
  Patterns for Mold MakingAF 4.3
 6.4 Solid ImagingAF 4.4
  3-Dimensional Scientific Graphical AnalysisAF 4.4
  Imaging People, Inside and OutAF 4.4
  Other Imaging ApplicationsAF 4.4
 6.5 Digital SculptureAF 4.5
   hLink('web'
  Bathsheba Grossman
  Raw Material
III Tomorrow
 7 Fabber ScienceAF 8
 7.1 Carving
 7.2 Molding
 7.3 Adhesion
 7.4 Biological Adhesion
 7.5 Coatings
 7.6 PhotopolymersAF 8.1
  History and Development of PhotopolymersAF 8.1
  Polymer ChemistryAF 8.1
  PhotopolymersAF 8.1
 7.7 Sintering of Thermoplastic PowdersAF 8.2
  History and Development of SinteringAF 8.2
  The Physics of SinteringAF 8.2
 7.8 Drop Deposition
 8 Technology DevelopmentAF 3, 10.1
  Technology Generations
 8.1 Gen 1: Improvements in Subtractive Fabrication
 8.2 Gen 2: Improvements in Flat-Layer FabricationAF 3.1
  Surface Laser Cure
  Pattern Cure
  Thermal and Electro-Cure
  Sintering
  Ink-Jet Fabbing
 8.3 Gen 3: Freeform FabricationAF 3.2
  Hybrid Process
  Robotic Interface
  Pattern Lamination
  Continuous Deposition
  Open Format Fabrication
  Interior Cure
  Droplet Deposition
  Formative Fabricatioon
  Distributed Process
  Incorporating 1- and 2-D Materials
 8.4 Gen 4: NanofabricationAF 3.4
  Surface Texture
  Fabbed-In Mechanisms
  Electronic Circuitry
  Other Nanotechnology
  Incorporating Fluids
  Guided AccretionFabber Revolution
  Artificial Embryology
 8.5 Materials Technology
  Composite Materials
  Structured Material
  Smart MaterialsAF 7.2
  Fabbing Living Tissue
  Matter Recycling or Material Reconsumption
 8.6 Control Technology
  3-D Geometrical Representation
  3-D Graphical User Interface
  Software: Matter Programming Languages
  Software: Nonserial Computation
 8.7 Scenes from the FutureUPS Foretells Fabbers
  The Scuba Fin
  The Trombone
  Bottled Water
  “Genuine” Leather Football
  The Household Fabber
 9 Applications Development
 9.1 Market Segments
 9.2 Design Iteration
 9.3 Freelance FabbingProf. Home Fabbing
 9.4 CustomationCustomation
  Mass Customization
  Customer CoconstructionAF 9.2
 9.5 e-FabNapster Fabbing
  Fabbers and the Internet —' + '
' + hBlank5 + '21' + aSym['st'] + '-Century Product Fulfillment
  Napsterization of Manufacturing
 9.6 Fabbers in SpaceAF 10.2
  Introduction
  What Shall We Make?
  Suitability of Processes for Space-Based Fabrication
  Process Schematics
  Raw Material
  Benefits
  Next Steps
  Conclusion
IV People and Business
 10 The Digital EconomyAF 9
 10.1 Emancipating TechnologyFree to Create
 10.2 Undoing the Industrial RevolutionAutoFab Future
  Putting the “Man” Back in Manufacturing
  Economy of Scale
  DecentralizationAtoms fr Bits
  Restructuring Labor and EmploymentAtoms fr Bits
 10.3 The New Inventor ClassAtoms fr Bits
 10.4 The New Value ChainAtoms fr Bits
 10.5 Entrepreneurial OpportunitiesAF 9.3
  Process Invention and Product DevelopmentAF 9.3
  Maneuvering through the Second Industrial RevolutionAF 9.3
 10.6 Impact of Digital Manufacturing on SocietyAF 9.1
 11 Transition from Industrial ManufacturingAF 5
 11.1 Operating Within the Industrial Paradigm
 11.2 Industrial/Digital Relationship
  The Industrial Ecosystem
  Product Process Analysis
 11.3 Technology SelectionAF 5.1
  Deciding Whether to Go DigitalAF 5.1
  Analyzing the Costs and BenefitsAF 5.1
  Deciding Which Fabricator to UseAF 5.1
  The Bottom Line in Selecting a Fabricator
  Selling the Concept to ManagementAF 5.1
 11.4 Installation and OperationAF 5.2
  Tips for Productive Use
  Downsizing
  Organizational Issues
  Periodic Review
 11.5 Using Fab ShopsAF 5.3
  Choosing a ShopAF 5.3
  Quality and Costs of ServicesAF 5.3
Appendices
 14 Teaching Fabbing
   The Author


POOFF! There it is!Digital Manufacturing
University of Southern California
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University of Southern California, Los Angeles, California
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