This thesis examines process planning for rapid die tooling. Sheet metal die tooling typically requires long lead times from design to manufacturing. Rapid manufacturing of die tooling is a method that reduces lead times by minimizing the process planning time. This research focuses on the process planning algorithm for laminated die manufacture to automatically provide adequate interlaminate strength using a minimum number of fasteners.

A mechanical model was developed for predicting shear and compressive forces during sheet metal bending was developed as an input to a bolt and dowel pin algorithm. An algorithm is described for proper placement of bolts and dowel pins per each slice layer to satisfy the mechanical model. The impact of this research will allow for proper design to achieve mechanical requirements of die tooling in a rapid manufacturing technology.