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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

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principles of digital manufacturing, but detailed information on machines, materials, processes, and applications is outdated.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 5 levels of topic detail. Change to 1/ 2/ 3/ 4 levels.
Topic							Based 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	Dedication				AF
		undefined	Foreword				AF
		undefined	Preface				AF
			undefined	Audience			AF
				undefined	What This Book Is Not
			undefined	Organization of the Book			AF
			undefined	Units of Measure			AF
				undefined	Metric Units
				undefined	“English” Units
			undefined	Terminology			AF
				undefined	Ennex-Speak
			undefined	Acknowledgments			AF
				undefined	Contributors, Reviewers, and Corroborators
			undefined	An Invitation to the Reader			AF
I	Groundwork
	1	Introduction to Digital Manufacturing					AF 1
		1.1	What is Manufacturing
				What do we make?
				Elements of Manufacturing
				Making Objects
					Classification of Fabrication Processes
						Three Basic Shaping Processes
						Automation of the Shaping Process
					A new verb, “fab”
				Paradigms of Manufacturing
				Economic Role of Manufacturing
				The Manufacturing Market
		1.2	What is Digital
		1.3	Digital Manufacturing				AF 1
				A New Paradigm
				Modern Tools
					Scanners
				Fabbers
					Fabber Processes of Today and Tomorrow
						Subtractive fabrication
						Flat-layer additive fabrication
						Improvements in flat-layer techniques
						Improvements beyond flat layers
					What’s Available
					Criteria for Digital Fabrication
					Automated Subtractive Fabrication: CNC Milling, Versatile CNC Machining, Micromachining
					Automated Additive Fabrication: StereoLithography, 3-D Printing, Many Others
						Process diagrams
					Tension between Additive and Subtractive Processes
					Automated Formative Fabrication: No Independent Working Processes Yet
				How Digital Manufacturing is Used
					Rapid Prototyping
					Advantages Within the Industrial Paradigm
				Considerations
					When to Use Digital Manufacturing
					Why Use It?
					Limitations
					What Digital Fabrication Enables
						What Additive Fabrication Enables
				Terminology
					Other Terms Used for Digital Fabrication
					Conflicting Use of the Word “Fabricate”
				What To Make
				The Digital Manufacturing Market			AF 1
					Market segments
					Market Size
					Is there a market for personal fabricators?
				Markets
	2	A Brief History of Manufacturing
				The Pace of Change
		2.1	Natural Ways of Making Things
				Cosmogony: Creation of Matter
					Matter and Stars
					Rocks and Planets
					Secondary Rock Processes
				Embryology: Growth of Living Organisms
				Natural Habitat Construction
					Termite Mounds
					Burrowing
					Spider Webs
					Bird Nests and Beavers Dams
				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: Molding			AF App. B
					Some Common Molding Processes
					Methods of Making Molds
					Mold Materials
		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
					The Fabber Revolution
					The Dark Side
II	Digital Manufacturing Today
	3	Digital Design					AF 6
		3.1	3-D Shape Representation				Data Formats
				3-D Data Formats
					Listing of Formats
					Fabber Formats
						NC Code
						StL Code
						Proposed Alternatives to StL
				Data Transfer
				Data Translators
				The StL Format
					Format Specifications
					StL ASCII Format
					StL Binary Format
		3.2	3-D CAD				AF 6.1
				Guidelines for Choosing a 3-D CAD Program
					Limitations on Geometry Input
					Quality of Output to Fabricators
					Other Communications
					Other Features to Look For
				A Selected List of 3-D CAD Programs
		3.3	Scanners				AF 6.2
				Levels of Digitization			AF 6.2
				The Elements of a 3-D Shape Digitizer			AF 6.2
				Types of Matter Sensors			AF 6.2
					Touch Probe and Trigger Sensors
					Optical Sensors
					Spatial Sensors
					Other Types of Matter Sensors
				Fabber Applications of 3-D Shape Digitization
					Hand Models
					Reverse Engineering
					Clothing
					Medical Applications
					Other Applications
		3.4	Mathematical Design				AF 6.3
		3.5	Related Software				AF 6.4
				Computer Visualization			AF 6.4
				Fabricator-Accessory Software
					Supports
					User Interface
		3.6	Related Hardware
				3-D Displays
	4	Digital Materials					AF 7
		4.1	An Introduction to Solid Materials				AF 7.1
		4.2	Properties of Solid Objects				AF 7.2
					Role of Structure in Properties
					Nonjudgmental Approach
					Types of Material Properties
				Smart Materials			AF 7.2
		4.3	A Partial Catalog of Properties of Solids				AF 7.3
				Inertial Properties			AF 7.3
				Interaction Properties			AF 7.3
					Mechanical Properties
					Thermal Properties
					Electromagnetic Properties
					Chemical Properties
					Economic Properties
				Properties Data for Common Solid Materials			AF 7.3
		4.4	Materials for Additive Fabrication				AF 7.4
					The Dual Role of Material Properties
					The Role of Additive Fabricators in Determining Properties
				Fabricated Millistructure at 3D Systems
				Curing Properties of Photopolymer Resins
				Properties Data for Commercial Fabricator Materials
					The Additive Materials Data Chart
					Wide Range of Properties
				Safety Issues of Fabricator Materials
					Toxicity of Photopolymer Resins
					Powder Concerns
				Metals by Additive Processes
	5	Digital Fabrication					AF 2
					Organization of this Chapter
				Table of Commercially Available Fabricators
					Specification Tables on the Individual Machines
		5.1	CNC Machining				AF 2.1
					Small Selection of Subtractive Fabricators in this Section
					Process Optimization
				A Few Examples of Milling Machines
					The Planer-Type Machining Center: Giddings & Lewis
					The BostoMatic: Boston Digital
					The DrillMill: Kira Machinery
					The proLight: Light Machines
				Lathes
					The LR Series: Okuma
					The Unimat PC: Emco Maier
				Wire EDM
					The “A” Series: Sodick
		5.2	Pattern Lamination				AF 2.4
				Bond-First Pattern Lamination: Helisys
				Shearing and Bending
					The S4+P4: Salvagnini
					The Fabriduct: Iowa Precision
		5.3	Continuous Deposition				AF 2.3
				Robotically Guided Extrusion: Stratasys
		5.4	Droplet Deposition				AF 2.3
				Droplet Deposition on Powder: Soligen
		5.5	Selective Sintering				AF 2.3
				Selective Sintering: DTM
					Patents on Laser Sintering
		5.6	Selective Curing				AF 2.2
					Pros and Cons of Some Distinctions
					Modern Photopolymer Properties
				Patent and Development History
					The Demise of the Mark 1000
				StereoLithography: 3D Systems
					Business Affairs
				Other Laser Curing
					The SOUP: CMET
					The Solid Creator: Sony
					The Stereos: EOS
					The Soliform: Teijin Seiki
				Masked-Lamp Curing: Cubital
					Other Attempts
					The Solider 5600
		5.7	Fabber Spec Tables
				Specification Tables on the Individual Machines
	6	Digital Products					AF 4
				Uses and Users: What Are Fabbers Used For?
		6.1	Direct Fabber Manufacturing				AF 4.1
					Large Objects
					Small Objects
					Unique Objects
					Machining in Plastic
					Machining on a Lathe
				Production by Additive Fabricators
					Pioneering Applications
					Criteria for Proliferation
				Case Studies
					Aerospace Parts
					Example 2
					Example 3
					Prostheses and Body Parts
		6.2	Models and Prototypes				AF 4.2
					Reasons for Building Models and Prototypes
					Testing Functionality
					Testing Fluid Flow
					Testing Fit
					Checking Designs
					Submission with Bid Requests
				Iteration for Satisfaction and Optimization			AF 4.2
				Case Studies
					Manufacturing Design
					Architectural Design
					Movie and Theater Props and Sets
		6.3	Replication Tooling				AF 4.3
				Direct Generation of Molds			AF 4.3
				Patterns for Mold Making			AF 4.3
					Soft Molds
					Expendable Molds
					Hard Molds
		6.4	Solid Imaging				AF 4.4
					Applications of Solid Imaging
				3-Dimensional Scientific Graphical Analysis			AF 4.4
						Scientific Models: Insights Better than 15 Years of Research
				Imaging People, Inside and Out			AF 4.4
					3-Dimensional Portraits
					3-Dimensional “X-Rays”
						Surgical Planning: Healing a Young Boy
				Other Imaging Applications			AF 4.4
		6.5	Digital Sculpture				AF 4.5
				hLink('web'
				Bathsheba Grossman
				Raw Material
					George Hart’s course
III	Tomorrow
	7	Fabber Science					AF 8
		7.1	Carving
					History of Carving Technology
					The Physics of Carving
		7.2	Molding
					History of Molding
					The Physics and Chemistry of Hardening in Shape
		7.3	Adhesion
					History of Adhesives
					The Physics and Chemistry of Adhesion
		7.4	Biological Adhesion
					Subsection 1
					Subsection 2
					Subsection 3
		7.5	Coatings
					History of Coatings
					The Physics and Chemistry of Coatings
					Coatings on Coatings
		7.6	Photopolymers				AF 8.1
				History and Development of Photopolymers			AF 8.1
				Polymer Chemistry			AF 8.1
					Definition of “Polymer” and Explanation of Properties
					Polymerization: How Polymers Grow
					Making Polymers Even Stronger: Crosslinking
					Polymers as Monomers
				Photopolymers			AF 8.1
					Photoinitiated Radical Polymerization
					Photocrosslinking
					Special Characteristics of Photopolymers
		7.7	Sintering of Thermoplastic Powders				AF 8.2
				History and Development of Sintering			AF 8.2
				The Physics of Sintering			AF 8.2
					Powder Fabrication
					Compaction
					Sintering
					The Differences among Metals, Ceramics, and Plastics
					The Differences between Bulk Sintering and Laser Sintering
		7.8	Drop Deposition
					History of Drop Deposition
					The Mechanics of Drop Evolution
					The Physics of Drop Interaction
	8	Technology Development					AF 3, 10.1
					Process research: Learning to manipulate matter
				Technology Generations
					The 5' + aSym['th'] + ' Generation: Picofabrication
		8.1	Gen 1: Improvements in Subtractive Fabrication
					Micromachining
		8.2	Gen 2: Improvements in Flat-Layer Fabrication				AF 3.1
				Surface Laser Cure
					The COLAMM: Mitsui
					CNRS and Laser 3D
				Pattern Cure
					Photocuring through a Contact Window
				Thermal and Electro-Cure
					Selective Thermal Curing
					Selective Electrocuring
				Sintering
				Ink-Jet Fabbing
		8.3	Gen 3: Freeform Fabrication				AF 3.2
				Hybrid Process
				Robotic Interface
				Pattern Lamination
					Offset Fabbing
					Why Offset Fabbing?
					Form-In-Place Fabrication
					Form-then-Bond Fabrication
					The Speed Advantage
					Automating Form-then-Bond Fabrication
					Demonstrated Applications
					Conclusions
					Notes
				Continuous Deposition
					Robotic Extrusion
					3-D Welding
						Shape Welding: Thyssen
						Shape Melting: Babcock & Wilcox
						3-D Welding: University of Nottingham
				Open Format Fabrication
				Interior Cure
					Formigraphic Engine and Battelle
					CNRS
					Future Prospects
				Droplet Deposition
					An Example Droplet Deposition Process: Incremental Fabrication
				Formative Fabricatioon
				Distributed Process
				Incorporating 1- and 2-D Materials
		8.4	Gen 4: Nanofabrication				AF 3.4
					Laser-Induced Deposition
					Manipulation of Individual Atoms
					Other Ideas
				Surface Texture
				Fabbed-In Mechanisms
				Electronic Circuitry
				Other Nanotechnology
				Incorporating Fluids
				Guided Accretion			Fabber Revolution
				Artificial Embryology
		8.5	Materials Technology
				Composite Materials
				Structured Material
				Smart Materials			AF 7.2
				Fabbing Living Tissue
				Matter Recycling or Material Reconsumption
		8.6	Control Technology
				3-D Geometrical Representation
					Future Data Formats
					Artificial Embryology
				3-D Graphical User Interface
				Software: Matter Programming Languages
				Software: Nonserial Computation
		8.7	Scenes from the Future				UPS Foretells Fabbers
					Versatility, quality, and economy
					The lessons of history
				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 Fabbing				Prof. Home Fabbing
					Household Use		Household Fabber
					Children’s Use
					Commercial Use at Home
		9.4	Customation				Customation
				Mass Customization
				Customer Coconstruction			AF 9.2
					Examples of Customer Coconstruction
					Implementation of Customer Coconstruction
					Summary
		9.5	e-Fab				Napster Fabbing
				Fabbers and the Internet —' + ' ' + hBlank5 + '21' + aSym['st'] + '-Century Product Fulfillment
				Napsterization of Manufacturing
						Update, October 2001
		9.6	Fabbers in Space				AF 10.2
				Introduction
				What Shall We Make?
				Suitability of Processes for Space-Based Fabrication
					Selective sintering
					Aimed deposition
					Selective curing
				Process Schematics
					Solar heating
				Raw Material
				Benefits
				Next Steps
				Conclusion
IV	People and Business
	10	The Digital Economy					AF 9
		10.1	Emancipating Technology				Free to Create
						Freedom to Learn
						Freedom to Move
						Freedom to Create
						Supporting Infrastructure
		10.2	Undoing the Industrial Revolution				AutoFab Future
				Putting the “Man” Back in Manufacturing
				Economy of Scale
				Decentralization			Atoms fr Bits
				Restructuring Labor and Employment			Atoms fr Bits
		10.3	The New Inventor Class				Atoms fr Bits
		10.4	The New Value Chain				Atoms fr Bits
		10.5	Entrepreneurial Opportunities				AF 9.3
				Process Invention and Product Development			AF 9.3
				Maneuvering through the Second Industrial Revolution			AF 9.3
		10.6	Impact of Digital Manufacturing on Society				AF 9.1
					The Growth and Importance of Awareness in Society
					How Digital Manufacturing Can Affect Human Society
					Twenty-first-Century Society
	11	Transition from Industrial Manufacturing					AF 5
		11.1	Operating Within the Industrial Paradigm
		11.2	Industrial/Digital Relationship
				The Industrial Ecosystem
				Product Process Analysis
		11.3	Technology Selection				AF 5.1
				Deciding Whether to Go Digital			AF 5.1
					Check Published Claims
					A Unified Approach
				Analyzing the Costs and Benefits			AF 5.1
					Acquisition Costs
					Mitigation of Acquisition Costs
					Operating Costs
					Operating Benefits
					Mitigation of Operating Benefits
					Learn from Others’ Experience
				Deciding Which Fabricator to Use			AF 5.1
					Involve the Ultimate Users
					Shopping for a Fabricator
					Accuracy and Speed
					Special Notes on Accuracy
					Special Notes on Speed
					Public Benchmarking Efforts
					Comparing Subtractive and Additive Processes
					Advantages of Subtractive Fabrication over Additive
					Advantages of Additive Fabrication over Subtractive
				The Bottom Line in Selecting a Fabricator
				Selling the Concept to Management			AF 5.1
		11.4	Installation and Operation				AF 5.2
				Tips for Productive Use
				Downsizing
				Organizational Issues
				Periodic Review
		11.5	Using Fab Shops				AF 5.3
				Choosing a Shop			AF 5.3
					The Purchase/Contracting Decision
					Alternatives to Job Shops
				Quality and Costs of Services			AF 5.3
					Getting Good Service
					Getting Fast Service
					Costs of Using a Job Shop
					The Politics of Job Shops
					Conclusion
V	Appendices
					Survival and Growth
					Manufacturing Technology
					Automated Subtractive Fabrication
					Automated Additive Fabrication
					Droplet Deposition
					Three-Dimensional Welding
					Microfabrication
					Nanofabrication
					Manufacturing Management
					Implementation of Additive Fabricators
					Benchmarking of Subtractive Fabricators
					Benchmarking of Additive Fabricators
					Computer-Aided Design
					Machining
					Photopolymerization
					Sintering
	14	Teaching Fabbing
		The Author

Digital Manufacturing
University of Southern California

University of Southern California, Los Angeles, California
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