The key impediment to the widespread use of 3D layered fabrication like Shape Deposition Manufacturing (SDM) and Micro- electromechanical Systems (MEMS) processes is not the limitations of the processes themselves, but the ability of engineers to explore and master the expanded design space they enable. We are working on a design interface, comprising an exchange format and an accompanying suite of services, for these processes. This interface is based on formal representations of process-related constraints expressed in terms of three-dimensional design features with associated rules to ensure manufacturability.

The interface specification is being built in collaboration with process developers at Stanford University, Carnegie Mellon University and other institutions, and builds upon emerging standards for exchanging product specifications and representing manufacturing processes. In addition, the supporting communications infrastructure for exchanging design features, constraints, process capabilities and manufacturing analyses over the Internet is being developed.

A series of design exercises are also proposed. The exercises will explore the ability of designers to construct libraries of re-usable elements for complex electromechanical systems, will test the ability of these design elements to be scaled and miniaturized to take advantage of MEMS technology, and will explore the feasibility of integrating designs and processes from different institutions to create miniature electromechanical systems.

A more detailed illustration of the proposed infrastructure is available here.