Manufacturing Processes: From Design to Production

This module introduces the scope and significance of manufacturing worldwide, providing an overview of the course structure and key topics. It presents a framework for planning manufacturing processes and evaluating process performance based on four key attributes.

Skills you'll gain

This module covers machining, the most common process of material removal. It explores the mechanics of material deformation, estimates of material removal rate and cutting forces, practical aspects of turning and milling operations, and methods of machining advanced materials and complex parts.

Skills you'll gain

This module focuses on injection molding, the most widely used plastics manufacturing process. It covers process physics, rate-limiting steps, process parameters, thermoplastic materials, mold tooling design, and guidelines for defect prevention. Examples include molding of toy bricks, cups, and plastic furniture.

Skills you'll gain

This module addresses sheet forming of plastics and metals. It covers materials and process considerations, rate- and geometry-limiting aspects including springback and tearing, and explains various uses including manufacturing of plastic packaging and aluminum beverage cans. A supplement introduces other polymer forming processes for plastic bottles, bags, and large containers.

Skills you'll gain

This module introduces casting, a process where metal parts are made by solidification within a mold. It covers sand casting, die casting, and investment casting processes, as well as rate-limiting steps and factors governing part microstructure, quality, and cost.

Skills you'll gain

This module introduces the spectrum of additive manufacturing (AM) technologies, its key applications, and reasons for its rapid growth. It focuses in-depth on the three most prevalent AM processes: extrusion of polymers and composites (FFF/FDM), photopolymerization (stereolithography or SLA), and selective laser melting (SLM) of metals.

Skills you'll gain

This module explains basic statistical methods for analyzing, monitoring, and controlling process variation, including the use of control charts. It covers the critical differences between variation, tolerances, and quality, and introduces principles of precision metrology.

Skills you'll gain

This module introduces probability theory and queuing theory, providing analytical examples of simple manufacturing systems. It covers critical concepts such as production rate, capacity, and buffers, and offers simulations representative of the current state of the industry along with case study examples.

Skills you'll gain

This module presents a methodology for estimating manufacturing cost and its relationship to process details and production volume. It includes examples discussing the cost of making toy bricks, window glass, and smartphones, essential for effective scale-up.

Skills you'll gain

This module discusses the implications of energy consumption in manufacturing and product life cycles. It also introduces several types of robots used in manufacturing, compares their performance, and illustrates how robotics can improve production efficiency and quality.

Skills you'll gain

This module explains the process physics of microelectronics fabrication and PCB manufacturing. It covers techniques for assembling electronic components onto PCBs and discusses Cost, Rate, Quality, and Flexibility of different assembly techniques.

Skills you'll gain

This concluding module provides a brief summary of the course, highlights important emerging manufacturing technologies, and presents perspectives from instructors and guests on the exciting future of manufacturing.

Skills you'll gain