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The purpose of this paper is to present result obtained from a developed technology selection framework and provide a detailed insight into the risk calculations and their implications in manufacturing technology selection process.

The results illustrated in the paper are the outcome of an action research study that was conducted in an aerospace company.

The paper highlights the role of risk calculations in manufacturing technology selection process by elaborating the contribution of risk associated with manufacturing technology alternatives in the shape of opportunities and threats in different decision‐making environments.

The research quantifies the risk associated with different available manufacturing technology alternatives. This quantification of risk crystallises the process of technology selection decision making and supports an industrial manager in achieving objective and comprehensive decisions regarding selection of a manufacturing technology.

The paper explains the process of risk calculation in manufacturing technology selection by dividing the decision‐making environment into manufacturing and supply chain environment. The evaluation of a manufacturing technology considering supply chain opportunities and threats provides a broader perspective to the technology evaluation process. The inclusion of supply chain dimension in technology selection process facilitates an organisation to select a manufacturing technology not only according to its own requirements, but also according to the interest of its constituent supply chain.

This paper presents an overview on the Auto‐ID (Automatic Identification) technologies testbed that has been established at the University of Missouri‐Rolla (UMR) with the objective of supporting research, development, and implementation of Auto‐ID technologies in network‐centric manufacturing environments.

UMR's Auto‐ID testbed uses a unique hardware‐in‐the‐loop simulation methodology, which integrates decision‐making model development with the design of networking topology and data routing/scheduling schemes, in order to develop, test, and implement viable Auto‐ID solutions. The methodology is founded on a 3‐level integrated model: controller simulation, distributed controller simulation, and distributed controller simulation with hardware‐in‐the‐loop.

This paper discusses two case studies that highlight the effective use of RFID technology, its potential advantages, challenges, and deficiencies stemming from particular applications. These applications include dock doors, automated guided vehicles, conveyor and automated storage/retrieval systems, integration of RFID middleware with programmable logic controllers, and inventory management of time‐sensitive materials.

The paper presents an innovative idea: hardware‐in‐the‐loop simulation methodology to design automation systems. The approach has been implemented on a variety of applications, which are presented in the paper as case studies.

The purpose of this paper is to establish a model‐based framework allowing the simulation, analysis and optimization of friction stir welding (FSW) processes of metallic structures using industrial robots, with a particular emphasis on the assembly of aircraft components made of aerospace aluminum alloys.

After a first part of the work dedicated to the kinetostatic and dynamical identification of the robotic mechanical system, a complete analytical model of the robotized process is developed, incorporating a dynamic model of the industrial robot, a multi‐axes macroscopic visco‐elastic model of the FSW process and a force/position control unit of the system. These different modules are subsequently implemented in a high‐fidelity multi‐rate dynamical simulation.

The developed simulation infrastructure allowed the research team to analyze and understand the dynamic interaction between the industrial robot, the control architecture and the manufacturing process involving heavy load cases in different process configurations. Several critical process‐induced perturbations such as tool oscillations and lateral/rotational deviations are observed, analyzed, and quantified during the simulated operations.

The presented simulation platform will constitute one of the key technology enablers in the major research initiative carried out by NRC Aerospace in their endeavor to develop a robust robotic FSW platform, allowing both the development of optimal workcell layouts/process parameters and the validation of advanced real‐time control laws for robust handling of critical process‐induced perturbations. These deliverables will be incorporated in the resulting robotic FSW technology packaged for deployment in production environments.

The paper establishes the first model‐based framework allowing the high‐fidelity simulation, analysis and optimization of FSW processes using serial industrial robots.

The purpose of this paper is to propose two simple tools for the kinematic characterization of hexapods. The paper also aims to share the experience of converting a popular commercial motion base (Stewart‐Gough platform, hexapod) to an industrial robot for use in heavy duty aerospace manufacturing processes.

The complete workspace of a hexapod is a six‐dimensional entity that is impossible to visualize. Thus, nearly all hexapod manufacturers simply state the extrema of each of the six dimensions, which is very misleading. As a compromise, a special 3D subset of the complete workspace is proposed, an approximation of which can be readily obtained using a computer‐aided design (CAD)/computer‐aided manufacturing (CAM) software suite, such as computer‐aided 3D interactive application (CATIA). While calibration techniques for serial robots are readily available, there is still no generally agreed procedure for calibrating hexapods. The paper proposes a simple calibration method that relies on the use of a laser tracker and requires no programming at all. Instead, the design parameters of the hexapod are directly and individually measured and the few computations involved are performed in a CAD/CAM software such as CATIA.

The conventional octahedral hexapod design has a very limited workspace, though free of singularities. There are important deviations between the actual and the specified kinematic model in a commercial motion base.

A commercial motion base can be used as a precision positioning device with its controller retrofitted with state‐of‐the‐art motion control technology with accurate workspace and geometric characteristics.

A novel geometric approach for obtaining meaningful measures of the workspace is proposed. A novel, systematic procedure for the calibration of a hexapod is outlined. Finally, experimental results are presented and discussed.

This paper aims to investigate a stereo vision-based hybrid (additive and subtractive) manufacturing process using direct laser metal deposition, computer numerical control (CNC) machining and in-process scanning to repair metallic components automatically. The focus of this work was to realize automated alignment and adaptive tool path generation that can repair metallic components after a single setup.

Stereo vision was used to detect the defect area for automated alignment. After the defect is located, a laser displacement sensor is used to scan the defect area before and after laser metal deposition. The scan is then processed by an adaptive algorithm to generate a tool path for repairing the defect.

The hybrid manufacturing processes for repairing metallic component combine the advantages of free-form fabrication from additive manufacturing with the high-accuracy offered by CNC machining. A Ti-6Al-4V component with a manufacturing defect was repaired by the proposed process. Compared to previous research on repairing worn components, introducing stereo vision and laser scanning dramatically simplifies the manual labor required to extract and reconstruct the defect area’s geometry.

This paper demonstrates an automated metallic component repair process by integrating stereo vision and a laser displacement sensor into a hybrid manufacturing system. Experimental results and microstructure analysis shows that the defect area could be repaired feasibly and efficiently with acceptable heat affected zone using the proposed approach.

This paper aims to provide a comprehensive review of the state-of–the-art design methods for additive manufacturing (AM) technologies to improve functional performance.

In this survey, design methods for AM to improve functional performance are divided into two main groups. They are design methods for a specific objective and general design methods. Design methods in the first group primarily focus on the improvement of functional performance, while the second group also takes other important factors such as manufacturability and cost into consideration with a more general framework. Design methods in each groups are carefully reviewed with discussion and comparison.

The advantages and disadvantages of different design methods for AM are discussed in this paper. Some general issues of existing methods are summarized below: most existing design methods only focus on a single design scale with a single function; few product-level design methods are available for both products’ functionality and assembly; and some existing design methods are hard to implement for the lack of suitable computer-aided design software.

This study is a useful source for designers to select an appropriate design method to take full advantage of AM.

In this survey, a novel classification method is used to categorize existing design methods for AM. Based on this classification method, a comprehensive review is provided in this paper as an informative source for designers and researchers working in this field.

The purpose of this study is to explore the applications of 3D printing in space sectors. The authors have highlighted the potential research gap that can be explored in the current field of study. Three-dimensional (3D) printing is an additive manufacturing technique that uses metallic powder, ceramic or polymers to build simple/complex parts. The parts produced possess good strength, low weight and excellent mechanical properties and are cost-effective. Therefore, efforts have been made to make the adoption of 3D printing successful in space so that complex parts can be manufactured in space. This saves a considerable amount of both time and carrying cost. Thereof the challenges and opportunities that the space sector holds for additive manufacturing is worth reviewing to provide a better insight into further developments and prospects for this technology.

The potentiality of 3D printing for the manufacturing of various components under space conditions has been explained. Here, the authors have reviewed the details of manufactured parts used for zero-gravity missions, subjected to onboard international space station conditions and with those manufactured on earth. Followed by the major opportunities in 3D printing in space which include component repair, material characterization, process improvement and process development along with the new designs. The challenges like space conditions, availability of power in space, the infrastructure requirements and the quality control or testing of the items that are being built in space are explained along with their possible mitigation strategies.

These components are well comparable with those prepared on earth which enables a massive cost saving. Other than the onboard manufacturing process, numerous other components as well as a complete robot/satellite for outer space applications were manufactured by additive manufacturing. Moreover, these components can be recycled onboard to produce feedstock for the next materials. The parts produced in space are bought back and compared with those built on earth. There is a difference in their nature, i.e. the flight specimen showed a brittle nature, and the ground specimen showed a denser nature.

This review discusses the advancements of 3D printing in space and provides numerous examples of the applications of 3D printing in space and space applications. This paper is solely dedicated to 3D printing in space. It provides a breakthrough in the literature as a limited amount of literature is available on this topic. This paper aims at highlighting all the challenges that additive manufacturing faces in the space sector and also the future opportunities that await development.

This paper aims to illustrate the tolerance optimization method based on the assembly accuracy constrain, precession constrain and the cost of production of the assembly product.

A tolerance optimization method is an excellent way to perform product assembly performance. The tolerance optimization method is adapted to the process analysis of the hatch and skin of an aircraft. In this paper, the tolerance optimization techniques are applied to the tolerance allocation for step difference analysis (example: step difference between aircraft cabin door and fuselage outer skin). First, a mathematical model is described to understand the relationship between manufacturing cost and tolerance cost. Second, the penalty function method is applied to form a new equation for tolerance optimization. Finally, MATLAB software is used to calculate 170 loops iteration to understand the efficiency of the new equation for tolerance optimization.

The tolerance optimization method is based on the assembly accuracy constrain, machinery constrain and the cost of production of the assembly product. The main finding of this paper is the lowest assembly and lowest production costs that met the product tolerance specification.

This paper illustrated an efficient method of tolerance allocation for products assembly. After 170 loops iterations, it founds that the results very close to the original required tolerance. But it can easily say that the different number of loops iterations may have a different result. But optimization result must be approximate to the original tolerance requirements.

It is evident from Table 4 that the tolerance of the closed loop is 1.3999 after the tolerance distribution is completed, which is less than and very close to the original tolerance of 1.40; the machining precision constraint of the outer skin of the cabin door and the fuselage is satisfied, and the assembly precision constraint of the closed loop is satisfied.

The research may support further research studies to minimize cost tolerance allocation using tolerance cost optimization techniques, which must meet the given constrain accuracy for assembly products.