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Several new production cost-tolerance models and a hybrid-model tolerance optimization formulation for tolerance synthesis are presented. These new models are introduced based upon the empirical cost-tolerance data of typical production processes, including hole producing, turning, milling, grinding and casting. The introduced models fit empirical cost-tolerance data with considerably less errors, and provide more reliable results for tolerance synthesis. In addition, the hybrid-model tolerance optimization formulation provides further modeling error reduction. The systematic evaluation of various cost-tolerance models provides model selection guidelines for tolerance synthesis. A typical tolerance design example is used to illustrate the method.

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Increasing competition in the global marketplace demands products with better functionality, higher quality, lower cost, shorter delivery lead time, and increased environmental friendliness. Although advanced manufacturing technologies can partially address these challenges, advanced design technologies are considered critical, since most design and manufacturing properties of a product are influenced by the design decisions made in the early design stages. This paper provides a comprehensive review on a new design paradigm — adaptable design — that aims at developing adaptable products to satisfy the various requirements of customers. The topics discussed in this review include the fundamental concepts, objectives, methodologies, and applications. The paper also presents the differences between adaptable design and other design methods, such as modular design, platform design, and product customization. The focus is on mechanical product design; however, potential applications of adaptable design in other disciplines are also briefly mentioned.

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