ME 6222: Manufacturing Processes and Systems

Offered Every Fall

Credit Hours: 3-0-3
Prerequisites: ME 4210 or equivalent; or with the consent of the instructor
Catalog Description: Materials processing analysis and selection. Manufacturing systems design. Economic analysis.
Textbooks: George Tlusty, Jiri Tlusty, Manufacturing Processes and Equipment, 1st Edition, Addison-Wesley, 1999.
Instructors: Jonathan Colton
Goals: To provide graduate students with an integrated treatment of the analysis of traditional and non-traditional manufacturing processes, their selection and planning, within an economic framework.
  • Review of material properties and behaviors
  • Review of manufacturing processes
  • Process Capabilities:
    • Geometry (size)
    • Complexity (1D, 2D, 3D)
    • Tolerance/ precision
    • Surface finish/ roughness
    • Numbers (one-off, small lot, mass production)
    • Material properties related:
      • Hardness
      • Melting temperature
  • Process economics
    • Cost
    • Economies of scale
  • Manufacturing Systems Design:
    • Matching product to processes (what are the steps)
  • Process selection models and methods:
    • Integration of process capabilities and economics
    • Inspection/SPC
    • Virtual factories
    • Robotics / Assembly
  • Specific Processes (a few selected from):
  • Material Removal Processes
    • Cutting
    • EDM/ ECM
    • Welding
    • Laser machining
  • Metal Deformation Processes
  • Polymer and Composites Processing
  • Electronics Manufacturing
    • Silicon manufacture
    • PWB manufacture
    • PWB population and attachment
  • Ceramic Processing
  • Powder Processing/Metallurgy
Course Format:

The course will be taught in two segments. The first segment will introduce the fundamental topics. These will provide a common background for all of the students and for the second segment of the course.

The second segment will focus on specific processes and products. A number of products, which undergo multiple manufacturing processes, will form the centerpieces of the second segment. These topics will be introduced by the instructors. Students will examine and analyze the products and determine the most cost effective set of processes that will produce the product. A manufacturing system design and analysis will be a typical output (mini-project).

Delivery mode (%):



Independent Study


Grading Scheme (%):



Individual Projects


Group Projects