Relating additive and subtractive processes in a teleological and modular approach

Purpose - The purpose of this paper is to relate additive manufacturing (AM) and machining (CNC) synergistically in a modular approach in the design and manufacturing domains, to generate value for end-users and manufacturers (a teleological system). Design/methodology/approach - The research methodology decomposes a part into modules, by employing a teleological systems theory approach paired with principles of modular design. Modules are manufactured with either additive manufacturing (fused deposition modeling, FDM) or machining (CNC). Process selection is determined by a decision-making framework that quantifies strength and weakness comparisons of FDM and CNC machining processes, accomplished using the analytic hierarchy process (AHP). Findings - The developed methodology and decision-making framework is successfully applied to the design and manufacturing of a large, complex V6 engine section sand casting pattern. This case study highlights the merits of the research. Research limitations/implications - The research assumes that the processes being considered are capable of meeting the product functional requirements. The proposed methodology can be extended to evaluate additional processes. Practical implications - Value is assessed in this research relative to: time and cost opportunities, managing knowledge limitations of a process by leveraging hybrid options, and aligning design and manufacturing to create a product that accomplishes the goals of the end-user (teleological effectiveness). Originality/value - Utilizing the AHP process and a teleological perspective are new, and proven effective, approaches in relating additive and subtractive processes in a hybrid approach with end-user perspectives. The research demonstrates a systematic methodology to quantify additive and subtractive process selection.