Bonding Issues

Lightweight automotive seats offermultiple benefits to original equipment manufacturers in terms of cost savings from various aspects, including less material usage, more integrated processes, and compliance with Corporate Average Fuel Economy Standards. Original equipment manufacturers have been focusing on innovative ways toproducelight weightautomotive seats. The commercially available automotive seats are currently made of multiple metal components combined through welding and fasteners. The use of additive manufacturing andcomposite structures is particularly useful for light weighting the automotive components. Additive manufacturing (AM) offers multiple advantages over traditional manufacturing processes such as freedom of design thereby enabling complex structural geometries, mass customization and waste minimization, and control over the fiber alignment through deposition in a predetermined pattern.Combining metal inserts with polymer composites through a novel manufacturing process allows design of lightweight and high-performance materials for automotive components. However, fabricating these metal polymer composite structures through traditional manufacturing processes limits their mechanical properties due to limited design freedom, lack of control over fiber orientation in composite parts, and poor interfacial bonding between the constituent materials. It is essential to develop a novel manufacturing process to enable high throughput production of lightweight automotive seats using metal and polymer composites. As such it is important to design the automotive seatsuitable for manufacturing viathis process and perform mechanical characterization on varioussubcomponents of the seat to ensure that the design and performance requirements provided by the auto manufacturer are met. The aim of this project is to develop a novel manufacturing technique to produce lightweight automotive seat by combining AM with conventional manufacturing processes. The car seat back panel will be designed via topology optimization and numerical simulations to minimize the overall weight while ensuring it meets all the performance requirements. The optimization of the seat back structure will be based on computational stress analysis to maximize the stiffness and minimize the weight. Materials currentlyused by Ford Motor Company will be adopted for a few subcomponents while the in-house composite materials will be used for the rest of the seat back. The composite and metallic materials will be tested to determinetheir mechanical properties as these are necessary for simulations. A novel manufacturing process will be developed to integrateAM metal inserts with discontinuous reinforced composite through large scale additive manufacturing and compression overmolding processes. The developed manufacturing technique will be used to fabricated various subcomponents suitable for the seat back design and mechanically tested to determine their properties. The manufacturing of the lightweight seat back design through this process involves integratedAM metal inserts with the composite structure forrecliner connection. The manufacturing of the entire seat back which is lightweight through the novel manufacturing process will be discussed. The performance of the designed seat back will be investigated through numerical simulations and shown to meet all the requirements provided by the auto manufacturer. The final goal of developing a novel manufacturing process for lightweight automotive seats is met through designoptimization of seat back,manufacturing of subcomponents, mechanical characterization, and validation through numerical simulations. The routes to achieve the final goal of the project and the depth in which they were investigated changed throughout the project due to personnel changes and the COVID-19 pandemic. The project resulted in the development of a novel manufacturing process to integrate metal inserts with tailored polymer composite preforms through overmolding. Leveraging this proven manufacturing process, a lightweight seat back was designed through topology optimization and numerical simulations. The designed seat back uses AM metal inserts and compression overmolding of tailored polymer composite preforms obtained via large scale additive manufacturing. The metal polymer composite 2| P a g estructures fabricated through this process exhibited enhancement in stiffness and improved ductility upon testing. Overall, the project provided an alternativedesign and manufacturing technique for automotive seat back that enables weight saving while meeting the safety and performance requirements.

The term “sustainable” itself has a very broad perspective, even in terms of manufacturing processes. Sustainability can be linked to a number of parameters for any manufacturing process. Advancements in manufacturing and materials processing technologies have made conventional processes of manufacturing and materials processing obsolete in many aspects. However, the focus is still on reducing the overall manufacturing cost by targeting specific parameters in terms of lower consumption of energy, lower processing time, better-quality product, lowering rejection rates, better scheduling, adopting lean manufacturing, and so on. These parameters can all be linked to sustainability of any manufacturing process. This chapter focuses on the need for sustainable developments in materials processing and the manufacturing sector. If sustainability is missing from the overall process, the process will be soon become outdated and obsolete. Researchers are continuously working in this area and trying to fix problems with innovative approaches. The techniques of hybridization of various processes are an example justifying the requirement of sustainable methods for manufacturing where the developed hybrid process offers enhanced output in comparison to conventional methods. The various inputs and outputs are the parameters that can be directly linked to the sustainability of any process. Initially, the sustainability of any process was discussed on the basis of the efficiency of the process, but it is now a well-known fact that sustainability can be divided into further multi-level objectives, which in turn drives the overall sustainability of a process. This chapter will highlight such sustainable requirements that are now an integral part of various manufacturing processes and materials processing technologies. A simple general model is proposed for measuring the sustainability index of any manufacturing process based on general parameters that are user defined.

Delivery of Obecabtagene Autoleucel (obe-cel, AUTO1) for the FELIX Pivotal Study Demonstrating Robust Cell Processing, Robust Release Testing, and Reliable Logistics, Together with Readiness for Sustainable Patient (pt) Care

Autonomic computing in manufacturing process coordination in industry 4.0 context

Manufacturing processes principally characterise the process manufacturing industries. The evolution of manufacturing processes has had a wide-ranging effect on problems that have emerged during the existence and development of process manufacturing industries. The series of changes and events that are taking place in manufacturing processes usually consist of a comprehensive integration of the mass flow, the energy flow, and the information flow. The science of metallurgical process engineering concerns the movement, transfer and chemical/physical transformations of mass flow, energy transfer and conversion, the relationships among materials and energy, and all other relevant information occurring at different levels, within different structures, and in different scales of the metallurgical manufacturing process. Its main intent is to study the structural evolution of the manufacturing process (the technological process of production) as well as the analysis/integration optimization of its structures and functions, or its restructuring optimization based on the integration optimization.

This paper presents a comprehensive approach to relocating and consolidating manufacturing lines and process equipment between plants efficiently and methodically. As global trends shift manufacturing operations from one region to another, the traditional AS IS Lift and Shift method often falls short in optimizing the manufacturing process. The proposed approach emphasizes redesigning and improving manufacturing processes to eliminate waste and enhance efficiency using advanced technologies combined with lean principles. This method promises significant benefits, including reduced lead times, improved quality, and lower manufacturing costs. The process is broken down into three main workstreams: Industrial and Manufacturing Engineering Planning, Production Control and Logistics Engineering Planning, and Program Management Support. Each workstream comprises detailed phases and steps that ensure a seamless transition. The paper highlights the importance of redesigning manufacturing processes, detailing decommissioning coordination at the origin plant, integrating and testing manufacturing processes at the target plant, and providing ongoing support during the manufacturing build and launch phase. Additionally, it underscores the need for meticulous logistics planning and robust program management to manage stakeholders, delivery, change, and risks effectively. Future work will explore integrating augmented, virtual, and mixed reality technologies to enhance planning, execution, and validation processes for even smoother transitions.

Recently, manufacturing technologies have progressed owing to high industrial demand. For example, in the automobile and aircraft industries, manufacturing processes require technologies that allow for high machining rates of lightweight and/or difficult-to-cut materials. Fabricating medical equipment involves the machining of biocompatible materials with high mechanical strength. Information devices require high-quality ultraprecision manufacturing processes. Furthermore, measurement and characterization technologies are also essential for manufacturing. Along with the evolution of manufacturing technologies, scientific studies have been performed on manufacturing phenomena and process control based on physical and/or mathematical aspects. This special issue was promoted by the International Conference on Leading Edge Manufacturing/Materials & Processing (LEM&P2023) held from June 12, 2023 to June 16, 2023 at Rutgers University in New Brunswick, sponsored by the Japan Society of Mechanical Engineers. This conference was co-located with the Manufacturing Science Engineering Conference (MSEC), ASME, and North American Manufacturing Research Conference (NAMRC), SME. This special issue includes nine papers that describe the innovations and detailed progress in the following areas: - Characterization of materials - Fundamental study and modeling of material removal process - Manufacturing control and optimization - Manufacturing processes for new hard materials - Micro-/Nano-scale manufacturing - Tool manufacturing and performance - Metrology and evaluation - Surface characterization This special issue includes technical and scientific discussions that suggest new key technologies for future manufacturing. We hope that this will help readers understand manufacturing processes and improve their operations. We thank the authors and reviewers for their generous cooperation and the editing staff for their contributions.

The deployment of additive manufacturing (AM) processes had a rapid and broad increase in the last years, and the same trend is expected to hold in the near future. A way to better exploit the advantages of such technology is the use of appropriate information tools. However, today there is a lack of software applications devoted to this innovative manufacturing process. To overcome this issue, in the present work the application of manufacturing execution systems (MES), a tool commonly used in traditional manufacturing processes, is extended to AM. Furthermore, a framework for the deployment of shop-floor data, acquired through a monitoring system, in the design phase is presented: hence, MES should cooperate with design for additive manufacturing (DFAM), a set of methods and tools helpful to design a product and its manufacturing process taking into account AM specificities from the early design stages. In order to better understand the advantages of such cooperation, a case study for a proof of concept has been developed: the obtained results are promising, thus an online implementation would be recommended.

Product reliability is determined by the design stage and qualified in the manufacturing stage. The fluctuations of manufacturing process result in inherent reliability lower than design reliability, called reliability degradation phenomenon. Based on the existing research on manufacturing system reliability and process reliability, this paper analyzes how the manufacturing process quality variation influences product reliability and studies the inhibition of product reliability degradation based on manufacturing process quality variation control. Firstly, the normal and abnormal manufacturing process fluctuations are explained and distinguished. After analyzing traditional process capability analysis, the Bayesian estimation based process capacity index analytical method aiming at the small batch production pattern is proposed and the superiority is verified. Finally, combined with state space model based variation source diagnosis, the framework of manufacturing process product reliability degradation inhibition is put forward.

New Trends in Manufacturing: Converging to Service and Intelligent Systems

The deployment of additive manufacturing (AM) processes had a rapid and broad increase in the last years, and the same trend is expected to hold in the near future. A way to better exploit the advantages of such technology is the use of appropriate information tools. However, today there is a lack of software applications devoted to this innovative manufacturing process. To overcome this issue, in the present work the application of manufacturing execution systems (MES), a tool commonly used in traditional manufacturing processes, is extended to AM. Furthermore, a framework for the deployment of shop-floor data, acquired through a monitoring system, in the design phase is presented: hence, MES should cooperate with design for additive manufacturing (DFAM), a set of methods and tools helpful to design a product and its manufacturing process taking into account AM specificities from the early design stages. In order to better understand the advantages of such cooperation, a case study for a proof of concept has been developed: the obtained results are promising, thus an online implementation would be recommended.

Over the past few decades, adoption of different Additive Manufacturing (AM) processes has gained momentum in the manufacturing industry. One such emerging AM process is wire-based directed energy deposition. Environmental impacts and costs are important criteria for adoption of any manufacturing process. Therefore, the aim of this paper is to evaluate the environmental and economic performance of Wire and Arc Additive Manufacturing (WAAM) using Life Cycle assessment (LCA) and Life Cycle Costing (LCC) methodologies. In this paper, an integrated methodology to conduct a cradle-to-gate LCA based on the guidelines of ISO 14044 and LCC based on IEC 60300–3–3 standards is proposed. A case study of a single steel wall manufactured by WAAM was analysed. The environmental impacts and production costs for wire-based directed energy deposition process were compared to laser powder bed fusion (LPBF) and Computer Numeric Control (CNC) milling processes. For the steel wall analysed, CNC milling was the most economical and ecological option followed by the wire-based directed energy deposition and LPBF. However, the performance of a process depends on product complexity and the manufacturing process’s material efficiency. Raw material production and labour were identified as major environmental hotspot and cost driver, respectively, in wire-based directed energy deposition. The methodology used in this paper can be extended to other manufacturing processes. The results of this study can help manufacturers in selecting manufacturing processes based on environmental impacts and production costs

Basic structure of lessons learned approach to improve manufacturing processes: A case study

Materials always in demand in everyday life of human beings and industries need as per applications. Every material has its properties. As per the demand for the desired object, raw materials changed through different manufacturing processes (shown in Figure 12.1). The manufacturing process also plays an important role, and today's improvement and development prospects in the manufacturing process help in energy-efficient manufacturing processes. An advanced method was developed for hybrid-micromachining operations per desired object shapes. And still, a researcher is researching to improve the manufacturing and machining process to improve its limitations during work. To maintain a sustainable hybrid-micromachining and hybrid-microfabrication process for industries. This study provides an overview analysis in detail of the various hybrid-micromachining process bibliometric survey, classification and machining mechanisms and their effective utilization of process parameters in the hybrid-micromachining (nanolevel, macrolevel, and microlevel) domain with particular emphasis.

The paper presents an ‘inverse’ method to teach specialist manufacturing processes by identifying a focal representative product (RP) from which, key specialist manufacturing (KSM) processes are analysed and interrelated to assess the capability of integrated manufacturing routes. In this approach, RP should: comprise KSM processes; involve innovative designs; be a daily used and/or market successful product; appeal to the profile of the course. The ‘inverse’ teaching method was implemented to a new third year specialist manufacturing module, manufacturing process capability through two stages as follows. Knowledge transfer that involved detailed teaching/analysis of technical capabilities of KSM processes through the decomposition of a focal RP, i.e. vacuum cleaner. Then, analysis of how entities (parts of RP) interact/couple to enable the generation of complex entities (assemblies of RP) was brought to students’ consideration. Knowledge exercise consisted of group/individual coursework assignments that were designed to stimulate students to use the RP approach for acquiring specialist manufacturing knowledge not discussed during the knowledge transfer stage. Furthermore, the KSM processes were exercised/coupled to generate new families of RPs. The evaluation and analysis of coursework assessments and the formal/informal feedback showed that this module helped students develop abilities to select and optimise capabilities of new manufacturing processes and then couple them to generate new RPs. However, it was found that students are less confident in dealing with inter-process/disciplinary topics that enable them to propose industrial viable manufacturing routes. Apart from individual circumstances, this might be due to previous engineering knowledge convened using by classical descriptive teaching approach. Additionally, the use of RP exercise offers an efficient method for ‘probing’ students’ abilities to interrelate key manufacturing processes for the generation of successful products are proposed.