(Re)Designing for Part Consolidation: Understanding the Challenges of Metal Additive Manufacturing

2015 ◽  
Vol 137 (11) ◽  
Author(s):  
John Schmelzle ◽  
Eric V. Kline ◽  
Corey J. Dickman ◽  
Edward W. Reutzel ◽  
Griffin Jones ◽  
...  
Keyword(s):  
Additive Manufacturing ◽  
System Level ◽  
Powder Bed ◽  
Part Consolidation ◽  
Case Part ◽  
Metallic Parts ◽  
Design Freedom ◽  
Am Processes ◽  
Metal Additive

Additive manufacturing (AM) of metallic parts provides engineers with unprecedented design freedom. This enables designers to consolidate assemblies, lightweight designs, create intricate internal geometries for enhanced fluid flow or heat transfer performance, and fabricate complex components that previously could not be manufactured. While these design benefits may come “free” in many cases, it necessitates an understanding of the limitations and capabilities of the specific AM process used for production, the system-level design intent, and the postprocessing and inspection/qualification implications. Unfortunately, design for additive manufacturing (DfAM) guidelines for metal AM processes are nascent given the rapid advancements in metal AM technology recently. In this paper, we present a case study to provide insight into the challenges that engineers face when redesigning a multicomponent assembly into a single component fabricated using laser-based powder bed fusion for metal AM. In this case, part consolidation is used to reduce the weight by 60% and height by 53% of a multipart assembly while improving performance and minimizing leak points. Fabrication, postprocessing, and inspection issues are also discussed along with the implications on design. A generalized design approach for consolidating parts is presented to help designers realize the freedoms that metal AM provides, and numerous areas for investigation to improve DfAM are also highlighted and illustrated throughout the case study.

scholarly journals Review of Powder Bed Fusion Additive Manufacturing for Metals

Metals ◽  
2021 ◽  
Vol 11 (9) ◽  
pp. 1391
Author(s):  
Leila Ladani ◽  
Maryam Sadeghilaridjani
Keyword(s):  
Additive Manufacturing ◽  
Three Dimensional ◽  
Disruptive Technology ◽  
Powder Bed ◽  
Powder Particles ◽  
Metallic Parts ◽  
The Cost ◽  
Scientific Questions ◽  
Metal Additive

Additive manufacturing (AM) as a disruptive technology has received much attention in recent years. In practice, however, much effort is focused on the AM of polymers. It is comparatively more expensive and more challenging to additively manufacture metallic parts due to their high temperature, the cost of producing powders, and capital outlays for metal additive manufacturing equipment. The main technology currently used by numerous companies in the aerospace and biomedical sectors to fabricate metallic parts is powder bed technology, in which either electron or laser beams are used to melt and fuse the powder particles line by line to make a three-dimensional part. Since this technology is new and also sought by manufacturers, many scientific questions have arisen that need to be answered. This manuscript gives an introduction to the technology and common materials and applications. Furthermore, the microstructure and quality of parts made using powder bed technology for several materials that are commonly fabricated using this technology are reviewed and the effects of several process parameters investigated in the literature are examined. New advances in fabricating highly conductive metals such as copper and aluminum are discussed and potential for future improvements is explored.

scholarly journals Analysis of Density, Roughness, and Accuracy of the Atomic Diffusion Additive Manufacturing (ADAM) Process for Metal Parts

Materials ◽  
2019 ◽  
Vol 12 (24) ◽  
pp. 4122 ◽  
Author(s):  
Manuela Galati ◽  
Paolo Minetola
Keyword(s):  
Additive Manufacturing ◽  
Layer Thickness ◽  
Dimensional Accuracy ◽  
Raw Material ◽  
Atomic Diffusion ◽  
Powder Bed ◽  
Metal Parts ◽  
Unique System ◽  
Am Processes ◽  
Metal Additive

Atomic Diffusion Additive Manufacturing (ADAM) is a recent layer-wise process patented by Markforged for metals based on material extrusion. ADAM can be classified as an indirect additive manufacturing process in which a filament of metal powder encased in a plastic binder is used. After the fabrication of a green part, the plastic binder is removed by the post-treatments of washing and sintering (frittage). The aim of this work is to provide a preliminary characterisation of the ADAM process using Markforged Metal X, the unique system currently available on the market. Particularly, the density of printed 17-4 PH material is investigated, varying the layer thickness and the sample size. The dimensional accuracy of the ADAM process is evaluated using the ISO IT grades of a reference artefact. Due to the deposition strategy, the final density of the material results in being strongly dependent on the layer thickness and the size of the sample. The density of the material is low if compared to the material processed by powder bed AM processes. The superficial roughness is strongly dependent upon the layer thickness, but higher than that of other metal additive manufacturing processes because of the use of raw material in the filament form. The accuracy of the process achieves the IT13 grade that is comparable to that of traditional processes for the production of semi-finished metal parts.

Failures Related to Metal Additive Manufacturing

2021 ◽  
pp. 250-265
Author(s):  
Daniel P. Dennies ◽  
S. Lampman
Keyword(s):  
Quality Control ◽  
Additive Manufacturing ◽  
Powder Bed Fusion ◽  
Key Factors ◽  
Powder Bed ◽  
Metal Additive Manufacturing ◽  
Design Considerations ◽  
Directed Energy ◽  
Am Processes ◽  
Metal Additive

Abstract This article provides an overview of metal additive manufacturing (AM) processes and describes sources of failures in metal AM parts. It focuses on metal AM product failures and potential solutions related to design considerations, metallurgical characteristics, production considerations, and quality assurance. The emphasis is on the design and metallurgical aspects for the two main types of metal AM processes: powder-bed fusion (PBF) and directed-energy deposition (DED). The article also describes the processes involved in binder jet sintering, provides information on the design and fabrication sources of failure, addresses the key factors in production and quality control, and explains failure analysis of AM parts.

A Design for Additive Manufacturing Ontology to Support Manufacturability Analysis

2018 ◽  
Author(s):  
Samyeon Kim ◽  
David W. Rosen ◽  
Paul Witherell ◽  
Hyunwoong Ko
Keyword(s):  
Additive Manufacturing ◽  
Design For Additive Manufacturing ◽  
Semantic Query ◽  
Ontology Language ◽  
Build Time ◽  
High Level ◽  
Design Freedom ◽  
Am Processes ◽  
Manufacturing Feature

Design for additive manufacturing (DFAM) provides design freedom for creating complex geometries and guides designers to ensure manufacturability of parts fabricated using additive manufacturing (AM) processes. However, there is a lack of formalized DFAM knowledge that provides information on how to design parts and how to plan AM processes for achieving target goals, e.g., reducing build-time. Therefore, this study presents a DFAM ontology using the web ontology language (OWL) to formalize DFAM knowledge and support queries for retrieving that knowledge. The DFAM ontology has three high level classes to represent design rules specifically: feature, parameter, and AM capability. Furthermore, the manufacturing feature concept is defined to link part design to AM process parameters. Since manufacturing features contain information on feature constraints of AM processes, the DFAM ontology supports manufacturability analysis of design features by reasoning with Semantic Query-enhanced Web Rule Language (SQWRL). The SQWRL rules in this study also help retrieve design recommendations for improving manufacturability. A case study is performed to illustrate usefulness of the DFAM ontology and SQWRL rule application. This study contributes to developing a knowledge base that can be reusable and upgradable and to analyzing manufacturing analysis to provide feedback about part designs to designers.

scholarly journals Metal Additive Manufacturing Cycle in Aerospace Industry: A Comprehensive Review

2019 ◽  
Vol 3 (3) ◽  
pp. 52 ◽  
Author(s):  
B. Barroqueiro ◽  
A. Andrade-Campos ◽  
R. A. F. Valente ◽  
V. Neto
Keyword(s):  
Additive Manufacturing ◽  
Aerospace Industry ◽  
Cost Effective ◽  
Comprehensive Review ◽  
Advanced Manufacturing Technologies ◽  
Manufacturing Technologies ◽  
Non Destructive ◽  
Am Processes ◽  
Metal Additive

Additive Manufacturing (AM) is the forefront of advanced manufacturing technologies and has the potential to revolutionize manufacturing, with a dramatic change in the design and project paradigms. A comprehensive review of existent metal AM processes, processable materials, respective defects and inspection methods (destructive and non-destructive) is presented in a succinct manner. Particularly, the AM design optimization methodologies are reviewed and their threats and constraints discussed. Finally, an aerospace industry case study is presented and several cost-effective examples are enumerated.

Additive Manufacturing Constraints in Topology Optimization for Improved Manufacturability

2018 ◽  
Vol 140 (5) ◽  
Author(s):  
Kunal Mhapsekar ◽  
Matthew McConaha ◽  
Sam Anand
Keyword(s):  
Topology Optimization ◽  
Additive Manufacturing ◽  
Experimental Validation ◽  
Manufacturing Processes ◽  
Manufacturing Constraints ◽  
Powder Bed Fusion ◽  
Powder Bed ◽  
And Topology ◽  
Am Processes

Additive manufacturing (AM) provides tremendous advantage over conventional manufacturing processes in terms of creative freedom, and topology optimization (TO) can be deemed as a potential design approach to exploit this creative freedom. To integrate these technologies and to create topology optimized designs that can be easily manufactured using AM, manufacturing constraints need to be introduced within the TO process. In this research, two different approaches are proposed to integrate the constraints within the algorithm of density-based TO. Two AM constraints are developed to demonstrate these two approaches. These constraints address the minimization of number of thin features as well as minimization of volume of support structures in the optimized parts, which have been previously identified as potential concerns associated with AM processes such as powder bed fusion AM. Both the manufacturing constraints are validated with two case studies each, along with experimental validation. Another case study is presented, which shows the combined effect of the two constraints on the topology optimized part. Two metrics of manufacturability are also presented, which have been used to compare the design outputs of conventional and constrained TO.

A Design for Additive Manufacturing Ontology to Support Manufacturability Analysis

2019 ◽  
Vol 19 (4) ◽  
Author(s):  
Samyeon Kim ◽  
David W. Rosen ◽  
Paul Witherell ◽  
Hyunwoong Ko
Keyword(s):  
Additive Manufacturing ◽  
Design For Additive Manufacturing ◽  
Design Features ◽  
Design Rules ◽  
Semantic Query ◽  
Ontology Language ◽  
Design Freedom ◽  
Am Processes ◽  
Manufacturing Feature

Design for additive manufacturing (DFAM) provides design freedom for creating complex geometries and guides designers to ensure the manufacturability of parts fabricated using additive manufacturing (AM) processes. However, there is a lack of formalized DFAM knowledge that provides information on how to design parts and how to plan AM processes for achieving target goals. Furthermore, the wide variety of AM processes, materials, and machines creates challenges in determining manufacturability constraints. Therefore, this study presents a DFAM ontology using the web ontology language (OWL) to semantically model DFAM knowledge and retrieve that knowledge. The goal of the proposed DFAM ontology is to provide a structure for information on part design, AM processes, and AM capability to represent design rules. Furthermore, the manufacturing feature concept is introduced to indicate design features that are considerably constrained by given AM processes. After developing the DFAM ontology, queries based on design rules are represented to explicitly retrieve DFAM knowledge and analyze manufacturability using Semantic Query-enhanced Web Rule Language (SQWRL). The SQWRL rules enable effective reasoning to evaluate design features against manufacturing constraints. The usefulness of the DFAM ontology is demonstrated in a case study where design features of a bracket are selected as manufacturing features based on a rule development process. This study contributes to developing a reusable and upgradable knowledge base that can be used to perform manufacturing analysis.

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 MODEL-BASED DESIGN OF AM COMPONENTS TO ENABLE DECENTRALIZED DIGITAL MANUFACTURING SYSTEMS

2021 ◽  
Vol 1 ◽  
pp. 2127-2136
Author(s):  
Olivia Borgue ◽  
John Stavridis ◽  
Tomas Vannucci ◽  
Panagiotis Stavropoulos ◽  
Harry Bikas ◽  
...  
Keyword(s):  
Additive Manufacturing ◽  
Manufacturing Systems ◽  
Production Systems ◽  
Data Generation ◽  
Production Networks ◽  
Model Based ◽  
Manufacturing Technologies ◽  
Am Processes ◽  
Final Consumer

AbstractAdditive manufacturing (AM) is a versatile technology that could add flexibility in manufacturing processes, whether implemented alone or along other technologies. This technology enables on-demand production and decentralized production networks, as production facilities can be located around the world to manufacture products closer to the final consumer (decentralized manufacturing). However, the wide adoption of additive manufacturing technologies is hindered by the lack of experience on its implementation, the lack of repeatability among different manufacturers and a lack of integrated production systems. The later, hinders the traceability and quality assurance of printed components and limits the understanding and data generation of the AM processes and parameters. In this article, a design strategy is proposed to integrate the different phases of the development process into a model-based design platform for decentralized manufacturing. This platform is aimed at facilitating data traceability and product repeatability among different AM machines. The strategy is illustrated with a case study where a car steering knuckle is manufactured in three different facilities in Sweden and Italy.

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