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Design for Rapid Manufacturing in an SME Environment
Dr Ian Campbell - Loughborough University
ABSTRACT - Rapid manufacturing (RM) provides a new freedom for component geometry and manufacturing batch sizes. This presentation will take the form of a case study based in a small UK company who recognised that they could benefit from these opportunities. The work followed on from the long-standing design for rapid manufacturing (DfRM) research at Loughborough University that had been undertaken within a series of projects. The aim of the work was to introduce DfRM into the company to help regenerate their product range. The project enabled the SME to learn many valuable lessons both in design and throughout the whole product development process. RM offered some unique geometric solutions, including ready-assembled ball joints, internal ducting and snap-fit assembly features. There were also some limitations on designs, in particular the achievable accuracy of assembly tolerances and minimum feature size. From the wider perspective, DfRM delivered design flexibility, rapid product development, economic small batch production and libraries of component families. Other important issues that were raised included the need for an in-house CAD capability and a close partnership with the RM service provider. The case study will provide other prospective users of RM with vital insight into the practicality of implementing a DfRM methodology.
Biography
After graduating from Brunel University in 1985, Dr Campbell worked as a design engineer in Ford Motor Company. He moved to the Rover Group in 1986 where again he was employed as a design engineer. Most of his design experience is with internal combustion engines. In 1989, Dr Campbell was appointed as a Senior Teaching Fellow for CAD/CAM at the University of Warwick. He remained in this position for four years, during which time, he undertook a part-time MSc degree by research. In 1993, Dr Campbell obtained a lectureship at the University of Nottingham and gained his PhD through part-time study in 1998. His current position is Reader in Computer Aided Product Design at Loughborough University in the Department of Design and Technology where he is leader of the Design Practice Research Group. His particular area of interest is in how the use of RP and RM will affect the design process. Dr Campbell is editor of the Rapid Prototyping Journal.
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