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This thesis presents a process planning methodology for a rapid injection mold tool manufacturing system that involves additive and subtractive techniques, whereby slabs are sequentially bonded and milled using layered tool paths. Mold tools are grown in a bottom up fashion, eliminating the need for multi-axis machining operations (beyond three axes) and allowing small features in deep cavities. In this research, a new layer bonding method using friction stir welding of aluminum plates is presented. In this manner, one can create seam-free laminated aluminum injection mold tooling using a unique combination of industrial adhesives and friction stir spot welding to initially secure the slab, then continuous friction stir welding of layer perimeters that are sequentially machined in a layer wise process. The original research is presented as a journal article. This research includes three areas of interest that will enable highly automated process planning. The first research area focuses on determining the process plan for applying adhesives on the laminated plates that will be sufficient to resist the forces acting on the plate due to subsequent friction stir spot welding. The use of fixtures and clamps for machining in rapid manufacturing create a potential problem for collision of the tool/spindle and the workpiece setup. Therefore, the process proposed in this thesis uses a combination of industrial adhesives and friction stir spot welding to secure the aluminum plates for machining. The second area focuses on determining the number, location and sequence of friction stir spot welds sufficient to secure the plate prior to continuous friction stir welding. The use of

Process planning for rapid manufacturing of plastic injection mold for short run production