Design Automation for Customised and Large-Scale Additive Manufacturing: A Case Study on Custom Kayaks

Drew Lithgow; Cara Morrison; George Pexton; Massimo Panarotto; Jakob R. Müller; Lars Almefelt; Andrew McLaren

doi:10.1017/dsi.2019.74

Additive Manufacturing Redesigning of Metallic Parts for High Precision Machines

Crystals ◽

10.3390/cryst10030161 ◽

2020 ◽

Vol 10 (3) ◽

pp. 161

Author(s):

Manuela Galati ◽

Flaviana Calignano ◽

Marco Viccica ◽

Luca Iuliano

Keyword(s):

Additive Manufacturing ◽

High Precision ◽

Testing Machine ◽

Cost Evaluation ◽

Inertial Forces ◽

Material Efficiency ◽

Design And Manufacturing ◽

Metallic Parts ◽

Precision Machines

The conventional approach to design and manufacturing often has geometries with an efficient material distribution. For the high-precision machines, that approach involves the design of heavy components that guarantees the stiffness requirements. However, the higher the weight of the part, the higher inertia it has. As a result, when the feed axes are accelerated, the inertial forces deform the machine components and the precision of the machine is reduced. This study investigated the designing for additive manufacturing (DfAM) and designing for assembly (DfA) to increase the material efficiency of components for high-precision applications. A new methodology which considered the design and manufacturing issues and machining as well is given. A comprehensive model for cost evaluation of the part is presented. The case study refers to the rails and the bracket that support and move the flying probe of a testing machine for micro-electromechanical systems (MEMS). The weight of the rails has been decreased by 32% and the components to be assembled have been reduced from 16 to 7. The optimized bracket is more than 50% stiffer than the original one, 10% lighter, and economically competitive.

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Design for Additive Manufacturing and Advanced Development Methods Applied to an Innovative Multifunctional Fan

International Journal of Manufacturing Materials and Mechanical Engineering ◽

10.4018/ijmmme.2019040101 ◽

2019 ◽

Vol 9 (2) ◽

pp. 1-32 ◽

Cited By ~ 1

Author(s):

Leonardo Frizziero ◽

Giampiero Donnici ◽

Alfredo Liverani ◽

Karim Dhaimini

Keyword(s):

Additive Manufacturing ◽

Quality Function Deployment ◽

Large Scale ◽

Three Dimensional ◽

Product Development Process ◽

Business Success ◽

Scale Production ◽

Business World ◽

Key Factor

In an increasingly competitive business world, the “time to market” of products has become a key factor for business success. There are different techniques that anticipate design mistakes and launch products on the market in less time. Among the most used methodologies in the design and definition of the requirements, quality function deployment (QFD) and design for Six Sigma (DFSS) can be used. In the prototyping phase, it is possible to address the emerging technology of additive manufacturing. Today, three-dimensional printing is already used as a rapid prototyping technique. However, the real challenge that industry is facing is the use of these machineries for large-scale production of parts, now possible with new HP multi-fusion. The aim of this article is to study the entire product development process taking advantage of the most modern models and technologies for the final realization of a case study that involves the design and prototyping of an innovative multifunctional fan (lamp, aroma diffuser and fan) through the Multi Jet Fusion of HP. To begin with, issues related to the DFSS, the QFD and their application to identify the fan requirements are explored. Once the requirements have been defined, the modern CAD design systems and the CAE systems for the validation of the case study will be analyzed and applied. Finally, HP's Multi Jet Fusion methodology and design rules for additive manufacturing will be analyzed in detail, trying to exploit all the positive aspects it offers.

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A design for additive manufacturing case study: fingerprint stool on a BigRep ONE

Rapid Prototyping Journal ◽

10.1108/rpj-10-2018-0278 ◽

2019 ◽

Vol 25 (6) ◽

pp. 1069-1079 ◽

Cited By ~ 5

Author(s):

James I. Novak ◽

Jonathon O’Neill

Keyword(s):

Additive Manufacturing ◽

Large Scale ◽

Future Research ◽

Design For Additive Manufacturing ◽

Fused Filament Fabrication ◽

Content Type ◽

Layer Height ◽

Design Engineers ◽

Final Design

Purpose This paper aims to present new qualitative and quantitative data about the recently released “BigRep ONE” 3 D printer led by the design of a one-off customized stool. Design/methodology/approach A design for additive manufacturing (DfAM) framework was adopted, with simulation data iteratively informing the final design. Findings Process parameters can vary manufacturing costs of a stool by over AU$1,000 and vary print time by over 100 h. Following simulation, designers can use the knowledge to inform iteration, with a second variation of the design being approximately 50 per cent cheaper and approximately 50 per cent faster to manufacture. Metrology data reveal a tolerance = 0.342 per cent in overall dimensions, and surface roughness data are presented for a 0.5 mm layer height. Research limitations/implications Led by design, this study did not seek to explore the full gamut of settings available in slicing software, focusing predominantly on nozzle diameter, layer height and number of walls alongside the recommended settings from BigRep. The study reveals numerous areas for future research, including more technical studies. Practical implications When knowledge and techniques from desktop 3 D printing are scaled up to dimensions measuring in meters, new opportunities and challenges are presented for design engineers. Print times and material costs in particular are scaled up significantly, and this study provides numerous considerations for research centers, 3 D printing bureaus and manufacturers considering large-scale fused filament fabrication manufacturing. Originality/value This is the first peer-reviewed study involving the BigRep ONE, and new knowledge is presented about the practical application of the printer through a design-led project. Important relationships between material volume/cost and print time are valuable for early adopters.

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Advanced Design Applied to an Original Multi-Purpose Ventilator Achievable by Additive Manufacturing

Applied Sciences ◽

10.3390/app8122635 ◽

2018 ◽

Vol 8 (12) ◽

pp. 2635 ◽

Cited By ~ 4

Author(s):

Leonardo Frizziero ◽

Giampiero Donnici ◽

Karim Dhaimini ◽

Alfredo Liverani ◽

Gianni Caligiana

Keyword(s):

Additive Manufacturing ◽

Quality Function Deployment ◽

Large Scale ◽

Product Development Process ◽

Scale Production ◽

Time To Market ◽

Design For Six Sigma ◽

Large Scale Production ◽

Design Systems

Considering the progressively expansive trade world, “time to market” of productions and goods has turned into a key element for business accomplishment. There are diverse practices that antedate design faults and unveil products on the market in minus time. Among the most used methods in the design and explanation of the necessities, quality function deployment (QFD) and design for Six Sigma (DFSS) can be used. In the prototyping stage, it is probable to address the emergent technology of additive manufacturing. Today, 3D printing is employed as a quick prototyping technique. Nevertheless, the tangible task which industry is fronting is the adoption of these machines for large-scale production of components, which is now possible with new HP multi fusion. The goal of this paper is to illustrate the entire product development process taking advantage of the most modern models and technologies for the final realization of a case study that involves the design and prototyping of an innovative multifunctional fan (lamp, aroma diffuser, and fan) through the multi jet fusion of HP. To begin with, issues related to the DFSS, the QFD and their application to identify the fan requirements are explored. Once the requirements have been defined, the modern CAD design systems and the CAE systems for the validation of the case study will be analyzed and applied. Finally, HP’s multi jet fusion methodology and design rules for additive manufacturing will be analyzed in detail, trying to exploit all the positive aspects it offers.

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Design for Additive Manufacturing and Advanced Development Methods Applied to an Innovative Multifunctional Fan

Additive Manufacturing ◽

10.4018/978-1-5225-9624-0.ch003 ◽

2020 ◽

pp. 52-85

Author(s):

Leonardo Frizziero ◽

Giampiero Donnici ◽

Alfredo Liverani ◽

Karim Dhaimini

Keyword(s):

Additive Manufacturing ◽

Quality Function Deployment ◽

Large Scale ◽

Three Dimensional ◽

Product Development Process ◽

Business Success ◽

Scale Production ◽

Key Factor ◽

Definition Of

In an increasingly competitive business world, the “time to market” of products has become a key factor for business success. There are different techniques that anticipate design mistakes and launch products on the market in less time. Among the most used methodologies in the design and definition of the requirements, quality function deployment (QFD) and design for Six Sigma (DFSS) can be used. In the prototyping phase, it is possible to address the emerging technology of additive manufacturing. Today, three-dimensional printing is already used as a rapid prototyping technique. However, the real challenge that industry is facing is the use of these machineries for large-scale production of parts, now possible with new HP multi-fusion. The aim of this article is to study the entire product development process taking advantage of the most modern models and technologies for the final realization of a case study that involves the design and prototyping of an innovative multifunctional fan (lamp, aroma diffuser and fan) through the Multi Jet Fusion of HP. To begin with, issues related to the DFSS, the QFD and their application to identify the fan requirements are explored. Once the requirements have been defined, the modern CAD design systems and the CAE systems for the validation of the case study will be analyzed and applied. Finally, HP's Multi Jet Fusion methodology and design rules for additive manufacturing will be analyzed in detail, trying to exploit all the positive aspects it offers.

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A Family With Autosomal-Dominant Progressive Sensorineural Hearing Loss

American Journal of Audiology ◽

10.1044/1059-0889.0501.23 ◽

1996 ◽

Vol 5 (1) ◽

pp. 23-32 ◽

Cited By ~ 3

Author(s):

Chris Halpin ◽

Barbara Herrmann ◽

Margaret Whearty

Keyword(s):

Speech Production ◽

Hearing Aids ◽

Role Models ◽

Speech Intelligibility ◽

Large Scale ◽

Speech Language Pathology ◽

The Family ◽

Patient Will ◽

Language Pathology

The family described in this article provides an unusual opportunity to relate findings from genetic, histological, electrophysiological, psychophysical, and rehabilitative investigation. Although the total number evaluated is large (49), the known, living affected population is smaller (14), and these are spread from age 20 to age 59. As a result, the findings described above are those of a large-scale case study. Clearly, more data will be available through longitudinal study of the individuals documented in the course of this investigation but, given the slow nature of the progression in this disease, such studies will be undertaken after an interval of several years. The general picture presented to the audiologist who must rehabilitate these cases is that of a progressive cochlear degeneration that affects only thresholds at first, and then rapidly diminishes speech intelligibility. The expected result is that, after normal language development, the patient may accept hearing aids well, encouraged by the support of the family. Performance and satisfaction with the hearing aids is good, until the onset of the speech intelligibility loss, at which time the patient will encounter serious difficulties and may reject hearing aids as unhelpful. As the histological and electrophysiological results indicate, however, the eighth nerve remains viable, especially in the younger affected members, and success with cochlear implantation may be expected. Audiologic counseling efforts are aided by the presence of role models and support from the other affected members of the family. Speech-language pathology services were not considered important by the members of this family since their speech production developed normally and has remained very good. Self-correction of speech was supported by hearing aids and cochlear implants (Case 5’s speech production was documented in Perkell, Lane, Svirsky, & Webster, 1992). These patients received genetic counseling and, due to the high penetrance of the disease, exhibited serious concerns regarding future generations and the hope of a cure.

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