scholarly journals Goal Oriented Provision of Design Principles for Additive Manufacturing to Support Conceptual Design

2019 ◽  
Vol 1 (1) ◽  
pp. 749-758 ◽  
Author(s):  
Felix Schumacher ◽  
Hagen Watschke ◽  
Sebastian Kuschmitz ◽  
Thomas Vietor
Keyword(s):  
Additive Manufacturing ◽  
Conceptual Design ◽  
Solution Space ◽  
Industrial Practice ◽  
Methodical Approach ◽  
Manufactured Products ◽  
Innovative Solution ◽  
End Use ◽  
The One ◽  
Design Freedom

AbstractAdditive Manufacturing (AM) offers a new degree in design freedom. However, in order to exploit AM's potentials in end-use products a methodical approach and suitable tools especially during conceptual design are needed. This paper presents a methodology for application in industrial practice, which should support the component conception for additively manufactured products. The approach focuses on a benefit-oriented preparation and provision of knowledge. In addition to general design methods for abstraction and promotion of creativity, AM-specific tools are introduced which support the provision of solution principles and process-specific restrictions. A broad applicability of the solution principles is ensured by an expansion of the solution space through abstraction. Consequently, product developers are sensitised to the new design possibilities of AM, on the one hand. On the other hand, they are supported in a holistic exploitation of design potentials in ideation in order to foster innovative solution ideas. Finally, the methodological procedure and the developed tools will be demonstrated in a workshop by using an example from industrial practice of the automotive sector.

scholarly journals A Methodical Approach to Support Conceptual Design for Multi-Material Additive Manufacturing

2019 ◽  
Vol 1 (1) ◽  
pp. 659-668 ◽  
Author(s):  
Hagen Watschke ◽  
Sebastian Kuschmitz ◽  
Julius Heubach ◽  
Guido Lehne ◽  
Thomas Vietor
Keyword(s):  
Additive Manufacturing ◽  
Conceptual Design ◽  
Methodological Approach ◽  
Functional Integration ◽  
Innovative Product ◽  
Specific Design ◽  
Design Engineers ◽  
Methodical Approach ◽  
Design Freedom ◽  
Design For Am

AbstractAdditive manufacturing (AM) opens new possibilities for innovative product designs. However, due to a lack of knowledge and restrained creativity because of design fixations, design engineers do not take advantage of AM's design freedom. Especially multi-material AM provides new opportunities for functional integration that hardly considered in ideation. To overcome barriers in the development of solution ideas and utilizing such new design potentials, new design methods and tools are needed. Therefore, in this contribution, a methodological approach for a function-oriented provision of solution principles specific to material extrusion is presented. A tool is developed to facilitate effective guidance in developing solution ideas and to foster a realistic concretization by providing a combination of opportunistic and restrictive AM knowledge. Besides general levers of AM, process-specific design opportunities support the design engineers in exploiting AM's potentials, especially those who are not familiar with Design for AM. Finally, the applicability of the methodological approach is evaluated in an academic study by means of redesigning a hand prosthesis with a grab function.

Contrasting Function With Affordance in Design for Additive Manufacturing

2017 ◽  
Author(s):  
Hyunwoong Ko ◽  
Seung Ki Moon
Keyword(s):  
Additive Manufacturing ◽  
Engineering Design ◽  
Conceptual Design ◽  
Design Method ◽  
Design Stage ◽  
Design Phase ◽  
Conceptual Design Phase ◽  
User Centric ◽  
Design Freedom ◽  
Mass Personalization

Additive Manufacturing (AM)’s advance from rapid prototyping to the end-of-use products inevitably challenges conventional design theories and methodologies. Especially while adopting systematic engineering design methodologies to design for AM (DfAM), it is essential to develop new design methods that explore the new design space enabled by AM’s design freedom from the early design stage. To address the challenge, this study provides a new design framework and a design method for modeling AM-enabled product behaviors in the conceptual design phase of DfAM. Firstly, this study contrasts function-based methods with affordance-based methods. The device-centric, form independent and input/output-based transformative properties of the function-based methods such as function decompositions have strengths in modeling product’s internal behaviors. However, the function-based methods show limitations in the new area of AM-enabled mass personalization which requires design approaches for representing user-centric structural design requirements acquired only by AM’s design freedom. On the other hand, the affordance-based methods can address the function-based methods in DfAM due to their user-centric (artifact-user interactive), form dependent and non-transformative properties. After the contradiction, we propose an affordance-based DfAM framework and an affordance structure as a formal modeling technique for AM-enabled personalized product behaviors. A case study of a trans-tibial prosthesis socket provides an illustration in this study. The contribution of the study is in developing a design method for the conceptual design phase of DfAM that fulfills the objectives of achieving AM-enabled mass personalization with systematic engineering design approaches.

scholarly journals SUPPORTING ADDITIVE MANUFACTURING TECHNOLOGY DEVELOPMENT THROUGH CONSTRAINT MODELLING IN EARLY CONCEPTUAL DESIGN: A SATELLITE PROPULSION CASE STUDY

2020 ◽  
Vol 1 ◽  
pp. 817-826
Author(s):  
O. Borgue ◽  
F. Valjak ◽  
M. Panarotto ◽  
O. Isaksson
Keyword(s):  
Additive Manufacturing ◽  
Conceptual Design ◽  
Technology Development ◽  
Manufacturing Technology ◽  
The Other ◽  
Additive Manufacturing Technology ◽  
Ion Thrusters ◽  
The Creation ◽  
Design Freedom

AbstractFunction and constraints modelling are implemented to design two gridded ion thrusters for additive manufacturing (AM). One concept takes advantage of AM design freedom, disregarding AM limitations and is not feasible. The other concept considers AM limitations and is manufacturable and feasible. Constraints modelling highlights AM capabilities that can be improved, showing where future investment is needed. Constraints representation can also support the creation of technology development roadmaps able to identify areas of AM technologies that must be improved.

scholarly journals Conception of Design Principles for Additive Manufacturing

2019 ◽  
Vol 1 (1) ◽  
pp. 689-698 ◽  
Author(s):  
Filip Valjak ◽  
Nenad Bojčetić
Keyword(s):  
Additive Manufacturing ◽  
Conceptual Design ◽  
Design Process ◽  
Design Principle ◽  
Design Principles ◽  
Product Architecture ◽  
Design Phase ◽  
Conceptual Design Phase ◽  
Design And Manufacturing ◽  
Design Freedom

AbstractAdditive Manufacturing (AM) brought new design freedom and possibilities that enable design and manufacturing of products with new forms and functionalities. To utilise these possibilities a new design approach emerged, Design for Additive Manufacturing (DfAM), that contains methods and tools for supporting AM oriented design process. Designers working with AM are aware of the need to apply DfAM and AM possibilities in conceptual design phase where they have the most significant influence on product architecture and form but are facing a lack of suitable DfAM approaches for early design phases. Therefore, the presented research is investigating possibilities of storing and representing AM knowledge in the form of design principles to be used in the conceptual design phase. The paper proposes conceiving of Design Principles for Additive Manufacturing repository where formalised AM knowledge is stored in the form of design principles and structured based on function criteria. In the paper, various elements of design principle representation are discussed, as well as their role in the conceptual design process.

scholarly journals A STRUCTURED APPROACH TO REDUCE DESIGN ITERATIONS IN ADDITIVE MANUFACTURING

2021 ◽  
Vol 1 ◽  
pp. 231-240
Author(s):  
Laura Wirths ◽  
Matthias Bleckmann ◽  
Kristin Paetzold
Keyword(s):  
Additive Manufacturing ◽  
Spare Parts ◽  
Design Guidelines ◽  
Final Part ◽  
Layer By Layer ◽  
Powder Bed ◽  
Batch Sizes ◽  
Manufacturing Technologies ◽  
Structured Approach ◽  
Design Freedom

AbstractAdditive Manufacturing technologies are based on a layer-by-layer build-up. This offers the possibility to design complex geometries or to integrate functionalities in the part. Nevertheless, limitations given by the manufacturing process apply to the geometric design freedom. These limitations are often unknown due to a lack of knowledge of the cause-effect relationships of the process. Currently, this leads to many iterations until the final part fulfils its functionality. Particularly for small batch sizes, producing the part at the first attempt is very important. In this study, a structured approach to reduce the design iterations is presented. Therefore, the cause-effect relationships are systematically established and analysed in detail. Based on this knowledge, design guidelines can be derived. These guidelines consider process limitations and help to reduce the iterations for the final part production. In order to illustrate the approach, the spare parts production via laser powder bed fusion is used as an example.

scholarly journals SURFACE ROUGHNESS CONSIDERATIONS IN DESIGN FOR ADDITIVE MANUFACTURING - A LITERATURE REVIEW

2021 ◽  
Vol 1 ◽  
pp. 2841-2850
Author(s):  
Didunoluwa Obilanade ◽  
Christo Dordlofva ◽  
Peter Törlind
Keyword(s):  
Surface Roughness ◽  
Additive Manufacturing ◽  
Literature Review ◽  
Future Research ◽  
Reduction Potentials ◽  
Research Fields ◽  
Post Process ◽  
Accessibility Issues ◽  
End Use ◽  
And Performance

AbstractOne often-cited benefit of using metal additive manufacturing (AM) is the possibility to design and produce complex geometries that suit the required function and performance of end-use parts. In this context, laser powder bed fusion (LPBF) is one suitable AM process. Due to accessibility issues and cost-reduction potentials, such ‘complex’ LPBF parts should utilise net-shape manufacturing with minimal use of post-process machining. The inherent surface roughness of LPBF could, however, impede part performance, especially from a structural perspective and in particular regarding fatigue. Engineers must therefore understand the influence of surface roughness on part performance and how to consider it during design. This paper presents a systematic literature review of research related to LPBF surface roughness. In general, research focuses on the relationship between surface roughness and LPBF build parameters, material properties, or post-processing. Research on design support on how to consider surface roughness during design for AM is however scarce. Future research on such supports is therefore important given the effects of surface roughness highlighted in other research fields.

Mechanical Response of Different Lattice Structures Fabricated Using the CLIP Technology

2016 ◽  
Author(s):  
Anil Saigal ◽  
John R. Tumbleston ◽  
Hendric Vogel
Keyword(s):  
Additive Manufacturing ◽  
Mechanical Response ◽  
Elastic Response ◽  
Lattice Structures ◽  
Rhombic Dodecahedron ◽  
Structured Materials ◽  
Specific Strength ◽  
Strain Behavior ◽  
End Use ◽  
Continuous Liquid Interface Production

In the rapidly growing field of additive manufacturing (AM), the focus in recent years has shifted from prototyping to manufacturing fully functional, ultralight, ultrastiff end-use parts. This research investigates the mechanical behavior of octahedral, octet, vertex centroid, dode, diamond, rhombi octahedron, rhombic dodecahedron and solid lattice structured polyacrylate fabricated using Continuous Liquid Interface Production (CLIP) technology based on 3D printing and additive manufacturing processes. The compressive stress-strain behavior of the lattice structures observed is typical of cellular structures which include a region of nominally elastic response, yielding, plastic strain hardening to a peak in strength, followed by a drop in flow stress to a plateau region and finally rapid hardening associated with contact of the deformed struts with each other as part of densification. It was found that the elastic modulus and strength of the various lattice structured materials are proportional to each other. In addition, it was found that the octahedral, octet and diamond lattice structures are amongst the most efficient based on the measured specific stiffness and specific strength.

Evaluation of Parts Produced by a Novel Additive Manufacturing Process

2013 ◽  
Vol 315 ◽  
pp. 63-67 ◽  
Author(s):  
Muhammad Fahad ◽  
Neil Hopkinson
Keyword(s):  
Additive Manufacturing ◽  
Rapid Prototyping ◽  
Manufacturing Process ◽  
High Speed ◽  
Three Dimensional ◽  
Coordinate Measuring Machine ◽  
Layer By Layer ◽  
Nylon 12 ◽  
Measuring Machine ◽  
End Use

Rapid prototyping refers to building three dimensional parts in a tool-less, layer by layer manner using the CAD geometry of the part. Additive Manufacturing (AM) is the name given to the application of rapid prototyping technologies to produce functional, end use items. Since AM is relatively new area of manufacturing processes, various processes are being developed and analyzed for their performance (mainly speed and accuracy). This paper deals with the design of a new benchmark part to analyze the flatness of parts produced on High Speed Sintering (HSS) which is a novel Additive Manufacturing process and is currently being developed at Loughborough University. The designed benchmark part comprised of various features such as cubes, holes, cylinders, spheres and cones on a flat base and the build material used for these parts was nylon 12 powder. Flatness and curvature of the base of these parts were measured using a coordinate measuring machine (CMM) and the results are discussed in relation to the operating parameters of the process.The result show changes in the flatness of part with the depth of part in the bed which is attributed to the thermal gradient within the build envelope during build.

Einbringen von Gewinden in SLM-Bauteile*/Insertion of threads into SLM components – Reliable strategy for inserting threads into additively manufactured components

2019 ◽  
Vol 109 (01-02) ◽  
pp. 24-29
Author(s):  
E. Abele ◽  
T. Scherer ◽  
F. Geßner ◽  
M. Weigold
Keyword(s):  
Additive Manufacturing ◽  
Selective Laser Melting ◽  
Downstream Processing ◽  
Manufacturing Processes ◽  
Laser Melting ◽  
Manufacturing Costs ◽  
Process Reliability ◽  
High Degree ◽  
Design Freedom ◽  
Processing Steps

Additive Fertigungsverfahren zeichnen sich durch große Gestaltungsfreiheit aus, welche die Herstellung komplexer Bauteile ermöglicht. Angesichts hoher Fertigungskosten ist die Prozesssicherheit nachgeordneter Bearbeitungsschritte (wie zum Beispiel die Gewindefertigung) von großer Bedeutung. Der Artikel stellt die Ergebnisse einer Untersuchungsreihe vor, die unterschiedliche Ansätze der Gewindefertigung in Bauteilen aus Stahl behandelt, die mittels Selektivem Laserschmelzverfahren gefertigt wurden.   Additive manufacturing processes are characterized by a high degree of design freedom to enablet the production of complex components. To reduce manufacturing costs, the process reliability of downstream processing steps (e. g. thread production) is of great importance. This article presents the results of a series of investigations dealing with different approaches to thread production in steel components manufactured by selective laser melting

scholarly journals Evaluating the Readiness Level of Additively Manufactured Digital Spare Parts: An Industrial Perspective

2018 ◽  
Vol 8 (10) ◽  
pp. 1837 ◽  
Author(s):  
Niklas Kretzschmar ◽  
Sergei Chekurov ◽  
Mika Salmi ◽  
Jukka Tuomi
Keyword(s):  
Additive Manufacturing ◽  
Manufacturing Industry ◽  
Spare Part ◽  
Spare Parts ◽  
Survey Study ◽  
Lead Times ◽  
Supply Networks ◽  
Readiness Level ◽  
End Use ◽  
Technological Limitations

Additive manufacturing of digital spare parts offers promising new possibilities for companies to drastically shorten lead times and to omit storage costs. However, the concept of digital spare parts has not yet gained much footing in the manufacturing industry. This study aims to identify grounds for its selective rejection. Conducted from a corporate perspective, outlining a holistic supply chain network structure to visualize different digital spare part distribution scenarios, this survey study evaluates technical and economic additive manufacturing capabilities. Results are analyzed and discussed further by applying the Mann-Whitney test to examine the influence of the company size and the presence of 3D-printed end-use components within supply networks on gathered data. Machines’ limited build chamber volumes and the necessity of post-processing are considered as the main technical challenges of current additive manufacturing processes. Furthermore, it can be concluded that company sizes have a significant effect on perceived technological limitations. Overall, the results lead to the conclusion that the readiness level of the digital spare parts concept demands for further development.

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