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Rosen, David W.

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    Designing Platforms for Customizable Produces and Processes in Markets of Non-Uniform Demand
    (Georgia Institute of Technology, 2007) Williams, Christopher Bryant ; Rosen, David W. ; Mistree, Farrokh ; Allen, Janet K.
    The foremost difficulty in making the transition to mass customization is how to offer product variety affordably. The answer to this quandary lies in the successful management of modularity and commonality in the development of products and their production processes. While several platform design techniques have emerged as a means to offer modularity and commonality, they are limited by an inability to handle multiple modes of offering variety for multiple design specifications. The Product Platform Constructal Theory Method (PPCTM) is a technique that enables a designer to develop platforms for customizable products while handling issues of multiple levels of commonality, multiple product specifications, and the inherent trade-offs between platform extent and performance. The method is limited, however, by its inability to handle multiple design objectives and its reliance on the assumption that demand in the market is uniform for each product variant. The authors address these limitations in this paper by infusing the utility-based compromise Decision Support Problem and demand modeling techniques. The authors further augment the PPCTM by extending it use to a new domain: the design of process parameter platforms. The augmented approach is illustrated through a tutorial example: the design of a product and a process parameter platform for the realization of a line of customizable cantilever beams.
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    Manufacturing Cellular Materials Via Three-Dimensional Printing of Spray-dried Metal Oxide Ceramic Powder
    (Georgia Institute of Technology, 2007) Rosen, David W. ; Williams, Christopher Bryant
    Cellular materials, metallic bodies with gaseous voids, are a promising class of materials that offer high strength accompanied by a relatively low mass. Unfortunately, existing manufacturing techniques constrain a designer to a predetermined part mesostructure, material type, and macrostructure. In this paper, the authors document their design rationale for the selection of the Three-Dimensional Printing (3DP) additive manufacturing process as a means to fabricate metallic cellular materials. This is achieved by selectively printing a solvent into a bed of spray-dried metal oxide ceramic powder. The resulting green part undergoes reduction and sintering post-production processes in order to chemically convert it to metal.
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    Towards the Design of a Layer-Based Additive Manufacturing Process for the Realization of Metal Parts of Designed Mesostructure
    (Georgia Institute of Technology, 2005) Mistree, Farrokh ; Rosen, David W. ; Williams, Christopher Bryant
    Low-density cellular materials, metallic bodies with gaseous voids, are a unique class of materials that have high strength, good energy absorption characteristics, good thermal and acoustic insulation properties, accompanied by an extremely low mass. Unfortunately, current cellular material manufacturing processes severely limit a designer's ability to control the part mesostructure, the material composition, and the part macrostructure. As such, the authors look towards the use of layer-based additive manufacturing (AM) as a means of providing the design freedom that is currently absent from cellular material manufacturing processes. Since current metal-based AM techniques do not offer an adequate means of satisfying the unique requirements of cellular materials, the authors carry out the conceptual design of a new AM process that is dedicated to the manufacture of cellular materials. Specifically, the authors look to the layer-based additive fabrication of metal oxide powders followed by post-processing in a reducing atmosphere as a means of fabricating three-dimensional, low-density cellular metal parts with designed mesostructure. In this paper, the authors detail this conceptual design process and select working principles that are worthy of further investigation. Insights gained as a result of designing an AM process for a specific class of geometry (e.g. considerations for small wall thickness, high quality surface finish, internal voids, and support material) and investigating the use of AM for production-scale manufacturing are also detailed.