Iterative Design Process Cycle

Laser transmission welding joins two overlapping thermoplastic parts by passing a laser beam through a laser-transmissive upper part to a laser-absorbent lower part. The absorbed laser energy heats and melts the interface. Clamping pressure fuses the molten layers, and upon cooling, a strong, clean weld is formed. This method is precise, non-contact, and creates minimal thermal stress or particulate contamination.

High-precision CNC machines employ a closed-loop control system to ensure accuracy. This system uses feedback devices, such as rotary encoders on servomotors or linear scales on the machine axes, to continuously monitor the machine's actual position. The controller compares this real-time feedback with the commanded position from the program and makes immediate corrections, compensating for errors.

Stereolithography is a vat photopolymerization additive manufacturing process. It employs an ultraviolet (UV) laser to selectively cure and solidify a liquid photopolymer resin. A build platform is submerged in the resin, and the laser traces a cross-section of the object on the surface. The platform then moves down by one layer thickness, allowing a new layer of resin to be cured on top.

Six Sigma is a disciplined, data-driven methodology for eliminating defects in any process – from manufacturing to transactional and from product to service. The statistical representation of Six Sigma describes a process where 99.99966% of all opportunities to produce some feature of a part are statistically expected to be free of defects (3.4 defects per million opportunities).

Selective Laser Sintering is a powder bed fusion additive manufacturing process. It utilizes a high-power laser to selectively sinter, or fuse, particles of a polymer powder. A roller spreads a thin layer of powder over a build area, the laser scans a cross-section of the part, and the build platform lowers. This process repeats, building the object layer-by-layer.

A patented form of ecological wastewater treatment and water reclamation system developed by Dr. John Todd. It uses a series of diverse ecosystems, including bacteria, algae, plants, snails, and fish, within controlled environments like tanks or greenhouses, to purify water. The system mimics the natural purification processes of wetlands and other aquatic ecosystems but in an intensified, engineered setting.

Phased Array Ultrasonic Testing (PAUT) employs a multi-element transducer where each element is pulsed independently with precise, computer-calculated time delays. By controlling this phasing, the resulting ultrasonic beam can be electronically steered, focused, and scanned without physically moving the probe. This provides rapid, detailed imaging of flaws, especially in complex geometries, surpassing conventional single-element techniques.

FMECA is an extension of FMEA that includes a criticality analysis, which charts the probability of failure modes against the severity of their consequences. This allows for a quantitative ranking of failure modes based on the combined influence of their severity and probability. The result highlights single points of failure and helps prioritize corrective actions based on a more rigorous risk level.

Concurrent engineering, also known as simultaneous engineering, is a design philosophy that emphasizes the parallelization of tasks. Instead of a sequential process where design is completed before manufacturing is considered, it involves a team-based approach where designers, manufacturing engineers, and other stakeholders work together from the outset. This overlap significantly reduces product development time and improves design quality.

The Juran Trilogy, developed by Dr. Joseph M. Juran, is a foundational quality management approach consisting of three interconnected processes: Quality Planning, Quality Control, and Quality Improvement. This framework provides a structured way for organizations to manage for quality. It emphasizes that quality does not happen by accident; it must be planned and managed systematically.

Parametric modeling is a CAD paradigm where designs are defined by parameters and constraints rather than just geometric shapes. Dimensions and relationships between features (e.g., parallelism, tangency) are stored as parameters. Modifying a parameter value automatically updates the entire model, maintaining the defined constraints. This approach facilitates design iteration, automation, and the creation of design families.