Manufacturing complexity evaluation at the design stage for both machining and layered manufacturing

In this paper, a methodology to estimate manufacturing complexity for both machining and layered manufacturing is proposed in order to realize tools (dies or molds) by a combination of a subtractive and an additive process. Manufacturability indexes are calculated at the tool design stage, these indexes provide an accurate view of which areas of the tool will advantageously be machined or manufactured by an additive process. In this case, tools are not seen as single pieces but as 3D puzzles with modules, manufactured aside by the best process and further assembled. (C) 2010 CIRP.