Abstract This paper presents results of exhaustive research in automated assembly planning. A generative assembly process planner (GAPP) has been developed that takes as input a solid model of the product to be assembled and outputs its feasible assembly sequences. Once the product has been modeled as a solid using a commercial solid modeler, the resulting solid model's boundary representation (B-Rep) file is interpreted by the GAPP to generate mating information among parts in the form of a relational graph. This graph becomes the input of a search graph process whose constrained expansion reveals all feasible assembly sequences from a geometric, stability, and accessibility point of view. The relative goodness of different feasible assembly sequences can be determined using pertinent criteria such as the number of reorientations involved or the clustering of similar assembly operations into successive ones. The expansion engine is very flexible and enables many different types of assembly problems to be handled uniformly, for example, finding disassembly repair sequences not requiring complete product disassembly or generating assembly sequences that force the building of predefined subassemblies. Examples with real industrial products are provided to illustrate the potential of using this tool.