The Design for Additive Manufacturing Worksheet

2016 ◽  
Author(s):  
Joran W. Booth ◽  
Jeffrey Alperovich ◽  
Tahira N. Reid ◽  
Karthik Ramani
Keyword(s):  
Additive Manufacturing ◽  
3D Printing ◽  
Prior Knowledge ◽  
High Volume ◽  
Visual Design ◽  
Design For Additive Manufacturing ◽  
Manufacturing Errors ◽  
Novice Users ◽  
Modern Manufacturing

Additive manufacturing (AM) technologies have become integral to the modern manufacturing process. These roles are filled both in prototyping and production. Many studies have been conducted and lists been written on guidelines for AM. While these lists are useful, virtually none are written in a way that is accessible to novice users of AM, such as Makers. Most guidelines assume the user has extensive prior knowledge of the process, apply to only a few AM technologies, or describe benefits of the technology that novices already know. In this paper, we present a short, visual design-for-additive-manufacturing worksheet for novice and intermittent users. It addresses common mistakes and problems as identified by various expert machinists and additive manufacturing facilities. The worksheet helps designers accurately assess the potential quality of a part that is to be made using an AM process by giving intuitive feedback and indirectly suggest changes to improve a design. The immediate benefit of this worksheet is that it can help to streamline designs and reduce manufacturing errors. We validated it in a high-volume 3D-printing facility (Boilermaker Lab) where users are predominantly novice or intermittent. After the worksheet was implemented in the Boilermaker Lab, both the rate of print failures and reprinted parts fell roughly 40%.

scholarly journals The Design for Additive Manufacturing Worksheet

2017 ◽  
Vol 139 (10) ◽  
Author(s):  
Joran W. Booth ◽  
Jeffrey Alperovich ◽  
Pratik Chawla ◽  
Jiayan Ma ◽  
Tahira N. Reid ◽  
...  
Keyword(s):  
Additive Manufacturing ◽  
Prior Knowledge ◽  
Real World ◽  
High Volume ◽  
Visual Design ◽  
Design For Additive Manufacturing ◽  
Novice Users ◽  
The Cost ◽  
Am Processes

Additive manufacturing (AM) technologies have become integral to modern prototyping and manufacturing. Therefore, guidelines for using AM are necessary to help users new to the technology. Many others have proposed useful guidelines, but these are rarely written in a way that is accessible to novice users. Most guidelines (1) assume the user has extensive prior knowledge of the process, (2) apply to only a few AM technologies or a very specific application, or (3) describe benefits of the technology that novices already know. In this paper, we present a one-page, visual design for additive manufacturing worksheet for novice and intermittent users which addresses common mistakes as identified by various expert machinists and additive manufacturing facilities who have worked extensively with novices. The worksheet helps designers assess the potential quality of a part made using most AM processes and indirectly suggests ways to redesign it. The immediate benefit of the worksheet is to filter out bad designs before they are printed, thus saving time on manufacturing and redesign. We implemented this as a go-no-go test for a high-volume AM facility where users are predominantly novices, and we observed an 81% decrease in the rate of poorly designed parts. We also tested the worksheet in a classroom, but found no difference between the control and the experimental groups. This result highlights the importance of motivation since the cost of using AM in this context was dramatically lower than real-world costs. This second result highlights the limitations of the worksheet.

Hybrid Metal 3D Printing for Selective Polished Surface

2021 ◽  
Vol 1027 ◽  
pp. 136-140
Author(s):  
Sze Yi Mak ◽  
Kwong Leong Tam ◽  
Ching Hang Bob Yung ◽  
Wing Fung Edmond Yau
Keyword(s):  
Additive Manufacturing ◽  
3D Printing ◽  
Surface Finishing ◽  
Polished Surface ◽  
Post Processing ◽  
One Stop ◽  
Metal 3D Printing ◽  
Critical Challenge ◽  
Metal Additive

Metal additive manufacturing has found broad applications in diverse disciplines. Post processing to homogenize and improve surface finishing remains a critical challenge to additive manufacturing. We propose a novel one-stop solution of adopting hybrid metal 3D printing to streamlining the additive manufacturing workflow as well as to improve surface roughness quality of selective interior surface of the printed parts. This work has great potential in medical and aerospace industries where complicated and high-precision additive manufacturing is anticipated.

What Is Design for Additive Manufacturing (DfAM)?

2020 ◽  
pp. 164-186
Author(s):  
Seung Hwan Joo ◽  
Sung Mo Lee ◽  
Jin Ho Yoo ◽  
Hyeon Jin Son ◽  
Seung Ho Lee
Keyword(s):  
Additive Manufacturing ◽  
3D Printing ◽  
Design Optimization ◽  
Advanced Manufacturing ◽  
Design For Additive Manufacturing ◽  
Printing Technology ◽  
Actual Production ◽  
Manufacturing Design ◽  
Metal 3D Printing ◽  
Is Design

In order to use 3D printing technology as a sanction, it is necessary to optimize topology, component unification, and reduce weight need for advanced manufacturing design. In the case of metal 3D printing, it is necessary to manage deformation and defects in the process cause of using laser, and support generation and design optimization must be accompanied for efficiency. Currently, design progresses through simulation before actual production in AM field. This chapter explores design in additive manufacturing.

Consideration of the Manufacturing Trajectories in a Global Design for Additive Manufacturing Methodology

2012 ◽  
Author(s):  
R. Ponche ◽  
O. Kerbrat ◽  
P. Mognol ◽  
J. Y. Hascoet
Keyword(s):  
Additive Manufacturing ◽  
Cost Reduction ◽  
Design Problem ◽  
Manufacturing Processes ◽  
Strong Impact ◽  
Direct Impact ◽  
Design For Additive Manufacturing ◽  
Physical Phenomena ◽  
Am Processes

Additive Manufacturing (AM) is a new way of part production which opens up new perspectives of conception as mass and cost reduction and increase of functionalities. However these processes have their own characteristics which as for all the manufacturing processes have a direct impact on the manufactured parts quality. Especially, because the manufacturing trajectories have a influence on the physical phenomena during the process, they have also a strong impact on the quality of the produced parts in terms of geometry. In this paper, the choice of manufacturing trajectories and their impacts on the final shape and quality of the parts is integrated into a global Design For Additive Manufacturing (DFAM) methodology which allows to move from functional specifications of a design problem to a proposition of an adapted part for AM processes.

scholarly journals Book review – Standards, quality control, and measurement sciences in 3D printing and additive manufacturing

2017 ◽  
Vol 3 (2) ◽  
Author(s):  
Tuan Anh Tran
Keyword(s):  
Quality Control ◽  
Additive Manufacturing ◽  
3D Printing ◽  
Fast Pace ◽  
Control Procedures ◽  
3D Printed

There is a gap between 3D Printing’s fast pace of development and the acceptance of 3D Printing technologies by other industries and applications. This hesitation comes mostly from unanswered questions about the consistency, reproducibility, and quality of 3D printed products. Although the list of excellent examples demonstrating its potential keeps expanding, a wide and thorough adoption of the technology requires crucial, yet currently missing elements including consensus standards, quality control procedures, and measuring methodologies. Progress in developing these elements, however, has been rather limited.

scholarly journals The Influence of Different Slicer Software on 3d Printing Products Accuracy and Surface Roughness

2021 ◽  
Vol 12 (2) ◽  
pp. 371-380
Author(s):  
Sally Cahyati ◽  
◽  
Haris Risqy Aziz
Keyword(s):  
Surface Roughness ◽  
Additive Manufacturing ◽  
3D Printing ◽  
3D Model ◽  
High Surface ◽  
3D Printer ◽  
Layer By Layer ◽  
Additive Manufacturing Technology ◽  
Printing Machine

Rapid Prototyping (RP) is a manufacturing process that produces a 3D model CAD to be a real product rapidly by using additive manufacturing technology. In this case, the product will print layer by layer uses a 3D printer machine. The 3D printer requires slicer software to convert CAD data into data that a 3D printer machine can read. Research is done to analyze the effect of three kinds of slicer software on 3D printing objects on the accuracy and surface roughness of the product. The 3D model CAD is sliced using three different slicer software, namely Ideamaker, Repetier Host, and Cura. The slice model result from each slicer will be printed on a 3D printer machine with the same process parameters to be compared. Then the product's dimensional and surface roughness will be measured to determine the effect of each slicer on product quality. The best quality of the product reflected the most suitable slicer software for the 3D printing machine that used. The best results achieved by Cura slicer because it has resulted in small dimensional deviations (max 0,0308±0,0079) and stabile high surface roughness of the product (max 1,585+059).

Impact of Timing in the Design Process on Students' Application of Design for Additive Manufacturing Heuristics

2021 ◽  
pp. 1-56
Author(s):  
Anastasia Schauer ◽  
Kenton Fillingim ◽  
Katherine Fu
Keyword(s):  
Additive Manufacturing ◽  
Design Process ◽  
Design Activity ◽  
Second Phase ◽  
Design For Additive Manufacturing ◽  
Additional Information ◽  
Design Heuristics ◽  
Traditional Manufacturing ◽  
The Way

Abstract The goal of this work is to study the way student designers use design for additive manufacturing (DfAM) rules, or heuristics. It can be challenging for novice designers to succeed at creating successful designs for additive manufacturing (AM), given its differences from traditional manufacturing methods. A study was carried out to investigate the way novices apply DfAM heuristics when they receive them at different points in the design process. A design problem was presented to students, and three different groups of student participants were given a lecture on DfAM heuristics at three different points in the design process. The novelty and quality of each of the resulting designs was evaluated. Results indicate that although the DfAM heuristics lecture had no impact on the overall quality of the designs generated, participants who were given the heuristics lecture after the initial design session produced designs that were better suited for 3D printing in the second phase of the design activity. However, receiving this additional information appears to prevent students from creatively iterating upon their initial designs, as participants in this group did not experience an increase in novelty between the two sessions. Additionally, receiving the heuristics lecture increased all students' perceptions of their ability to perform DfAM-related tasks. These results validate the practicality of design heuristics as AM training tools while also emphasizing the importance of iteration in the design process.

scholarly journals A bibliometric analysis of research in design for additive manufacturing

2022 ◽  
Vol ahead-of-print (ahead-of-print) ◽  
Author(s):  
Martins Ugonna Obi ◽  
Patrick Pradel ◽  
Matt Sinclair ◽  
Richard Bibb
Keyword(s):  
Additive Manufacturing ◽  
Bibliometric Analysis ◽  
Knowledge Development ◽  
Design For Additive Manufacturing ◽  
Global Knowledge ◽  
Content Type ◽  
Subject Areas ◽  
Manufacturing Knowledge ◽  
Bibliometric Approach

Purpose The purpose of this paper is to understand how Design for Additive manufacturing Knowledge has been developing and its significance to both academia and industry. Design/methodology/approach In this paper, the authors use a bibliometric approach to analyse publications from January 2010 to December 2020 to explore the subject areas, publication outlets, most active authors, geographical distribution of scholarly outputs, collaboration and co-citations at both institutional and geographical levels and outcomes from keywords analysis. Findings The findings reveal that most knowledge has been developed in DfAM methods, rules and guidelines. This may suggest that designers are trying to learn new ways of harnessing the freedom offered by AM. Furthermore, more knowledge is needed to understand how to tackle the inherent limitations of AM processes. Moreover, DfAM knowledge has thus far been developed mostly by authors in a small number of institutional and geographical clusters, potentially limiting diverse perspectives and synergies from international collaboration which are essential for global knowledge development, for improvement of the quality of DfAM research and for its wider dissemination. Originality/value A concise structure of DfAM knowledge areas upon which the bibliometric analysis was conducted has been developed. Furthermore, areas where research is concentrated and those that require further knowledge development are revealed.

Case study of the additive manufacturing application in the supersonic flow researches

2021 ◽  
Vol ahead-of-print (ahead-of-print) ◽  
Author(s):  
Jefte da Silva Guimarães ◽  
Valéria Serrano Faillace Oliveira Leite ◽  
Marco Antonio Sala Minucci ◽  
Dermeval Carinhana
Keyword(s):  
Additive Manufacturing ◽  
Supersonic Flow ◽  
3D Printing ◽  
Dimensional Change ◽  
Supersonic Combustion ◽  
Measuring System ◽  
Content Type ◽  
Before And After ◽  
New Perspective

Purpose The purpose of this paper is to demonstrate the aerodynamic behavior of a supersonic combustion test bench (SCTB) components, as the transition piece and the combustor of a scramjet (supersonic combustion ramjet), manufactured by 3D printing or additive manufacturing (AM). Design/methodology/approach For the dimensional and structural analysis of the manufactured models, a portable 3D scanner was used to generate the mesh of its dimensions, and to compare them before and after the experiments, a roughness measuring system was also used to verify the roughness inside the models before and after the tests, as roughness is an important parameter because it directly affects the boundary layer. For the visualization of the flow, the non-intrusive schlieren optical technique was used. Findings The experiments were carried out on the SCBT for Mach 2 flows, using the manufactured prototypes and showed that there was no structural and dimensional change of the model after the test batteries. It was found that the roughness presented by the material did not affect the quality of the flow generated. This shows that the investigated material can also be applied in experiments with supersonic flow. Originality/value This paper presents that it is possible to use in ground test facilities, for the studies of supersonic flow (in cold condition), pieces and models manufactured by 3D printing without affecting the quality of the flow generated during the experiments. This study presents a new perspective to approach AM applied in the studies of supersonic flows.

scholarly journals Additive manufacturing and technical strategies for improving outcomes in breast reconstructive surgery

ACTA IMEKO ◽  
2020 ◽  
Vol 9 (4) ◽  
pp. 74 ◽  
Author(s):  
Nicola Rocco ◽  
Ida Papallo ◽  
Maurizio Bruno Nava ◽  
Giuseppe Catanuto ◽  
Antonello Accurso ◽  
...  
Keyword(s):  
Additive Manufacturing ◽  
Reconstructive Surgery ◽  
Breast Implants ◽  
Porous Structures ◽  
Design For Additive Manufacturing ◽  
Design Strategies ◽  
Advanced Technologies ◽  
Patient Reported ◽  
Breast Reconstructive Surgery

It has been widely reported that breast reconstruction improves the quality of life of women who undergo mastectomy for breast cancer. <br />This approach provides many psychological advantages. Today, different techniques are available for the breast oncoplastic surgeon <br />that involve the use of breast implants and autologous tissues, also offering interesting results in terms of aesthetic and patient-reported <br />outcomes. On the other hand, advanced technologies and design strategies (i.e. design for additive manufacturing, reverse engineering) <br />may allow the development of customised porous structures with tailored morphological, mechanical, biological, and mass transport <br />properties. For this reason, the current study deals with the challenges, principles, and methods of developing 3D additive manufactured <br />structures in breast reconstructive surgery. Specifically, the aim was to design 3D additive manufactured poly(&amp;epsilon;-caprolactone) scaffolds <br />with different architectures (i.e. lay-down patterns). Preliminary mechanical and biological analyses have shown the effect of the lay-<br />down pattern on the performances of the manufactured structures.

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