Project MAXWELL: Towards Rapid Realization of Superior Products

We describe a new methodology for the design and manufacture of mechanical components. The methodology is a synergism of a new, mathematically rigorous procedure for the concurrent design of shape and material composition of components, and a new manufacturing process called MD* for their realization. The concurrent design strategy yields information about the global shape of the component and its material composition. The fabrication of such designs with novel microstructural configurations require unconventional manufacturing processes. MD* is a shape deposition process for the free-form fabrication of parts from single or composite materials and is ideally suited for realizing the aforementioned designs. Project MAXWELL, therefore, promotes the use of layered manufacturing beyond prototyping tasks and offers the possibility of their integration into the mainstream product development and fabrication process..Mechanical Engineerin

Manufacturing Mechatronics Using Thermal Spray Shape Deposition

A new technology for manufacturing mechatronics is described. The technique is based on recursive masking and deposition of thermally sprayed materials. Using these methods, mechanical structures can be created that embed and interconnect electronic components. This results in highly integrated mechatronic devices. A simple, electromechanical artifact was designed and produced to assess the feasibility of these techniques. The details and limitations of this project will be discussed. Areas of future research are identified which are aimed at realizing the full potential of this emerging manufacturing process.Mechanical Engineerin