LECTURER: MAX MUSTERMANN

MANUFACTURING METHODS
INDUSTRY 4.0
INTRODUCTORY ROUND

Who are you?

- Name
- Employer
- Position/responsibilities
- Fun Fact
- Previous knowledge? Expectations?
TOPIC OUTLINE

Introduction to Manufacturing Methods 1

Manufacturing Methods 2

Additive Manufacturing and 3-D Printing 3

Rapid Prototyping 4

Rapid Tooling 5
TOPIC OUTLINE

Direct/Rapid Manufacturing 6

Cyber-Physical Production Systems 7

10
U
UNIT 1

INTRODUCTION TO
MANUFACTURING METHODS
STUDY GOALS

- Learn the main sets of raw materials used in

manufacturing
- Understand material chemistry and physical
properties that affect final products
- Recognize and identify subtractive manufacturing
processes
- Recognize and identify additive manufacturing
methods
EXPLAIN SIMPLY

1. Which are the properties of metals?

2. Describe the subtractive and additive manufacturing
processes and how they differ.
3. Explain the industrial revolution timeline.
INTRODUCTION

Raw materials
(Metals, nonmetals)

Subtractive Manufacturing Additive Manufacturing

Source of the animated gif: giphy.com/TITANSofCNC, 2020; giphy.com/chaaaad, 2015.
RAW MATERIALS AND COST

PRODUCT COST

Raw materials
Raw material
(Metals, nonmetals) 50%

Source of the graphic: Adapted from S. Qiao, 2018.

MATERIALS

MATERIALS

METAL NONMETAL

FERROUS NONFERROUS ORGANIC INORGANIC

POLYMERES NONPOLYMERS CERAMICS GLASSES

COMPOSITES
MATERIAL GROUPING

Material Grouping
Main grouping of Manufacturing Materials and their basic properties
Properties Metals Nonmetals
Appearance Shiny Dull
Hardness Very hard or hard Brittle
Malleability Malleable Nonmalleable
Ductility Ductile Non-ductile
Heat conduction Good Bad
Electrical conduction Good conductor Bad conductor
State(s) Solid, liquid Solids, liquids, gases
Density Higher Lower

Source of the table: Course Book DLMBMMIIT02, p.13.

METALS

- Metals are shiny,

malleable, and good
conductors of heat
and electrical

Metals currents.

- Metals can be:

- Ferrous
- Nonferrous
Source of the graphic: Pixabay.
NONMETALS

Organic materials for

manufacture purposes
Can be melted repeatedly
polymers can be classified as :

- Thermoplastics Once shaped, cannot be melted

- Thermosetting polymers
- Elastomers
Feature elasticity

Source of the graphic: Power Point Stock Images.

NONMETALS

Inorganic materials are often

used in applications and
products that demand:

- High melting points

- Strength high or low
conduction.

(Glass, Ceramic, Composites)

Source of the graphic: Power Point Stock Images.

SUBTRACTIVE MANUFACTURING

Division:
1. Casting
2. Machining
3. Deformation
processes
4. Consolidation
processes
MILLING
Subtractive manufacturing accounts for 80% of all
operations
Source of the animated gif: giphy.com/TITANSofCNC, 2020.
ADDITIVE MANUFACTURING

Additive manufacturing processes:

1. Vat photopolymerization
2. Material jetting
3. Binder jetting
4. Powder bed fusion
5. Material extrusion
6. Directed energy deposition
7. Sheet lamination
Additive manufacturing accounts for only 20% of
MATERIAL EXTRUSION
all operations.
Source of the animated gif: giphy.com/chaaaad, 2015.
HISTORICAL DEVELOPMENT OF MANUFACTURING

Source of the table: Course Book DLMBMMIIT02, p.17.

ABOUT THE LONG TAIL

The long tail theory advocates production of

several different products in low volumes for two
reasons:

1. The cost of inventory is low

2. The bottom 80 percent of products could
encompass the future 20 percent of products

Source of the graphic: Power Point Stock Images.

REVIEW STUDY GOALS

- Learn the main sets of raw materials used in

manufacturing
- Understand material chemistry and physical
properties that affect final products
- Recognize and identify subtractive manufacturing
processes
- Recognize and identify additive manufacturing
methods
SESSION 1

TRANSFER TASK
TRANSFER TASK

1. What are the key differences between Metal and Nonmetal

Materials? Name examples of each.
2. Why does additive manufacturing account for 20% and
subtractive manufacturing for 80% of all operations? Is this
going to change?
TRANSFER TASK
PRESENTATION OF THE RESULTS

Please present your

results.
The results will be
discussed in
plenary.
LEARNING CONTROL QUESTIONS

1. The following are properties of metals, except…

a) non-ductile.
b) good heat conductor.
c) malleable.
d) very hard or hard.

2. A good explanation of the Third Industrial Revolution is…

a) the introduction of AI.
b) the automation and computerization of machinery.
c) the development of the assembly line.
d) the introduction of the steam engine.
LEARNING CONTROL QUESTIONS

3. The concept of the “long tail” in manufacturing can be described as…

a) mass production.
b) mass customization.
c) mass computerization.
d) mass input.
LIST OF SOURCES

Chaaaad (2015). Chaaaad GIF, Retrieved from https://giphy.com/gifs/3d-printing-kim-jong-un-pyonyang-3oEduFOgg5hPr8R6py, last checked 3 September 2021.
Qiao, S. (2018). Importance of Product Design for Manufacturing and Assembly, Retrieved from https://www.linkedin.com/pulse/importance-product-design-manufacturing-assembly-simon-qiao/, last checked 3
September 2021.
TITANSofCNC (2020). Boom Doosan GIF, Retrieved from https://giphy.com/gifs/TITANSofCNC-mynx-doosan-titans-of-cnc-8pJH0Fp4oMNArRAWyC, last checked 3 September 2021.
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