Component based design and digital manufacturing: a design for manufacturing model for curved surfaces fabrication using three axes computer numerical controlled router

Abstract

This thesis explores new ways to integrate manufacturing processes information in to design phases. Through the use of design for manufacturing (DfM) concept, and looking at relations between its potential application in architectural production and its implementation using digital manufacturing technologies, the author implemented a DfM model that varies from previous models by incorporated learning in the process. This process was based on the incremental development and refinement of design heuristics and metrics. The DfM model developed in this research is a process model to be implemented as a framework within educational settings. The proposed model is based in two basic strategies; first a process description in the form of alternative design strategies; and second, the implementation of design heuristics and design metrics. Subsequently, the author tested and refined the model using a sequence of case studies with students. In the final stage, the research evaluated and further developed the DfM model in a component design case study. The general purpose in performing this case studies sequence was to test the proposed DfM model. The second objective was to refine the DfM model by capturing knowledge from the case studies. As a summary, this research conceptualizes from this top-down development approach to create a design for manufacturing model that integrates design and construction in architecture, based on three possible applications fields; DfM teaching approaches development, design processes improvement; and DfM methods development. The final purpose is to provide better foundational constructs for architectural education and to improve teaching approaches that integrate design and manufacturing.