We describe a new methodology for the design and manufacture of mechanical
components. The methodology is a synergism of a new, mathematically rigorous
procedure for the concurrent design of shape and material composition of components,
and a new manufacturing process called MD* for their realization. The concurrent design
strategy yields information about the global shape of the component and its material
composition. The fabrication of such designs with novel microstructural configurations
require unconventional manufacturing processes. MD* is a shape deposition process for
the free-form fabrication of parts from single or composite materials and is ideally suited
for realizing the aforementioned designs. Project MAXWELL, therefore, promotes the use
of layered manufacturing beyond prototyping tasks and offers the possibility of their
integration into the mainstream product development and fabrication process..Mechanical Engineerin
