Non-Lamindated Machine Design

NON-LAMINATED MACHINE DESIGN Frederico A. Ramalho Filho et al.

Abstract

Purpose - The Non-Laminated Machine Design (nLMD) is a Rapid Prototyping and Manufacturing (RP/M) technique developed to solve several problems related to the design and construction of special robots and machines.

Design/methodology/approach - The nLMD is based on the product design methodology “Design for Manufacture and Assembly” (DFMA), the rapid prototyping method “Laminated Object Modeling” (LOM), and good manufacturing practices involved in LASER cutting of metals sheets and welding. The nLMD starts with the DFA optimization of the machine concept to minimize the number of parts followed by the breaking down of every part into two dimensional shapes of the same thickness using DFM, and ends by building the whole machine on a single LASER-cut metal sheet. These sub components are welded together with autogenous TIG welding.

Findings - This technique has been successfully used since 2004 for the construction of several machines, including welding robots, CNC mill and plasma table, welding jigs, and other manufacturing machines. Since it is based on simple rules, it is easy to learn and has been adopted by a growing number of other designers.

Originality/ Value – In some cases, the price reduction was over 80% when compared to conventional CNC milling of stock to manufacture a prototype. The technique lets all the components be manufactured in one step, allowing for hundreds of different parts to be build in a couple of hours from one metal sheet using LASER cutting with one G Code. This provides simplified logistics, low cost and an excellent turnover for the development of industrial machines.

Keywords: Welding, Metal cutting, LASER, LOM, DFMA, nLMD

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