Design Rules for Additive Manufacturing: A Categorization

2017 ◽  
Author(s):  
Mahesh Mani ◽  
Paul Witherell ◽  
Haeseong Jee
Keyword(s):  
Additive Manufacturing ◽  
New Product Development ◽  
Design Process ◽  
Process Planning ◽  
New Product ◽  
Industrial Applications ◽  
Design Rules ◽  
Geometrical Characteristics ◽  
Am Processes ◽  
Design For Am

Additive manufacturing (AM) is gaining popularity in industrial applications including new product development, functional parts, and tooling. However, due to the differences in AM technologies, processes, and process implementations, functional and geometrical characteristics of manufactured parts can vary dramatically. Planning, especially selecting the appropriate AM process and material requirements can be rather involved. Manufacturability using AM processes has been well studied; however, gaps exist in the design process when catering to the needs of manufacturability. Designers today are challenged with a lack of understanding of AM capabilities, process-related constraints, and their effects on the final product. Challenges are compounded by the ambiguity of where design for AM ends and process planning begins. These ambiguities can be addressed through design principles and corresponding design rules for additively manufacturing parts. The purpose of this paper is to categorically present relevant and reported efforts in design and process planning with design rules in AM. The overarching goal of the review is to offer insights to extract and categorize fundamental principles for derivative rules for different AM processes. Identifying such fundamental requirements could potentially lead to breakthroughs in design and process planning.

Proposing a Practical Method for Conceptual Design Process in New Product Development: Medical Glasses as a Case Study

2014 ◽  
Vol 3 (2) ◽  
pp. 80
Author(s):  
Amir Mirzadeh Phirouzabadi
Keyword(s):  
Product Development ◽  
Conceptual Design ◽  
New Product Development ◽  
Design Process ◽  
Quality Function Deployment ◽  
Early Stage ◽  
New Product ◽  
Practical Method ◽  
Effect Analysis ◽  
Quality Of Products

Nowadays,improving the quality of products, reducing cost and meeting customer’srequirements are necessary to shorten the time of new product development(NPD). NPD is used to describe the complete process of bringing a new product to market and conceptual design process(CDP) is at its early stage and has mostly changed from passive respond toaggressive one. Thus, this study proposed a practical method for CDP in NPDthrough three phases as Converting customers’ requirements to product specifications,Generating and selecting of concepts and Testing and finalizing the concepts byusing some different management-engineering techniques. Firstly, this papertried to prioritize customer’s requirements related to product by AHP (AnalyticHierarchy Process) and convert them to engineering parameters of TRIZ (Theoryof Inventive Problem Solving) in order to define the inventive principals.Next, based on QFD (Quality Function Deployment), we measured the weight valuesof inventive principals. Finally, as FMEA (Failure Mode and Effect Analysis)can analyze the weight values and reduce the sequential risk, then finalconceptual design was generated. At the end, a medical glasses was used as acase study of innovative design to validate the method and explain how thestrategies of this research for CDP.

But Will it Print?: Assessing Student Use of Design for Additive Manufacturing and Exploring its Effect on Design Performance and Manufacturability

2019 ◽  
Author(s):  
Rohan Prabhu ◽  
Scarlett R. Miller ◽  
Timothy W. Simpson ◽  
Nicholas A. Meisel
Keyword(s):  
Additive Manufacturing ◽  
Undergraduate Students ◽  
Educational Interventions ◽  
Support Material ◽  
Design Performance ◽  
Process Characteristics ◽  
Build Time ◽  
And Performance ◽  
Am Processes ◽  
Design For Am

Abstract Additive manufacturing (AM) enables engineers to improve the functionality and performance of their designs by adding complexity at little to no additional cost. However, AM processes also exhibit certain unique limitations, such as the presence of support material, which must be accounted for to ensure that designs can be manufactured feasibly and cost-effectively. Given these unique process characteristics, it is important for an AM-trained workforce to be able to incorporate both opportunistic and restrictive design for AM (DfAM) considerations into the design process. While AM/DfAM educational interventions have been discussed in the literature, limited research has investigated the effect of these interventions on students’ use of DfAM. Furthermore, limited research has explored how DfAM use affects the performance of students’ AM designs. This research explores this gap through an experimental study with 123 undergraduate students. Specifically, participants were exposed to either restrictive DfAM or dual DfAM (both opportunistic and restrictive) and then asked to participate in an AM design challenge. The students’ final designs were evaluated for (1) performance with respect the design objectives and constraints, and (2) the use of the various aspects of DfAM. The results showed that the use of certain DfAM considerations, such as minimum feature size and support material mass, successfully predicted the performance of the AM designs. Further, while the variations in DfAM education did not influence the performance of the AM designs, it did have an effect on the students’ use of certain DfAM concepts in their final designs. These results highlight the influence of DfAM education in bringing about an increase in students’ use of DfAM. Moreover, the results demonstrate the potential influence of DfAM in reducing build time and build material of the students’ AM designs, thus improving design performance and manufacturability.

scholarly journals Application of Axiomatic Design for Agile Product Development

2018 ◽  
Vol 223 ◽  
pp. 01004 ◽  
Author(s):  
Erik Puik ◽  
Dareks Ceglarek
Keyword(s):  
Product Development ◽  
New Product Development ◽  
Early Stage ◽  
Axiomatic Design ◽  
New Product ◽  
Agile Development ◽  
Design Rules ◽  
Iterative Development ◽  
Agile Design ◽  
Development Methods

Agile, and iterative, development methods for new product development are gaining in popularity under product engineers; where it initially was just applied for software development, now larger adoption takes place for product development in general. The design rules of agile development are somewhat conflicting with the guidelines of Axiomatic Design. In this paper, it is investigated why this is the case, what can be done about it, and how can the strengths of agile development be combined with Axiomatic Design to optimise methods for product design. It is shown that the methods are indeed advising on different and conflicting strategies, however, by attenuating the agile design rules in the early stage of design, and doing the same for AD in the later stage of design, best of both worlds can be combined.

scholarly journals Innovative Framework to manage New Product Development (NPD) Integrating Additive Manufacturing (AM) and Agile Management

Procedia CIRP ◽  
2021 ◽  
Vol 103 ◽  
pp. 128-133
Author(s):  
Júlia Fornaziero de Almeida ◽  
Daniel Capaldo Amaral ◽  
Reginaldo Teixeira Coelho
Keyword(s):  
Additive Manufacturing ◽  
Product Development ◽  
New Product Development ◽  
New Product

scholarly journals Comparing additive manufacturing technologies for customised wrist splints

2015 ◽  
Vol 21 (3) ◽  
pp. 230-243 ◽  
Author(s):  
Abby Megan Paterson ◽  
Richard Bibb ◽  
R. Ian Campbell ◽  
Guy Bingham
Keyword(s):  
Additive Manufacturing ◽  
Upper Extremity ◽  
Digital Design ◽  
Future Research ◽  
Fused Deposition Modelling ◽  
Full Potential ◽  
Content Type ◽  
Fused Deposition ◽  
Am Processes ◽  
Design For Am

Purpose – The purpose of this paper is to compare four different additive manufacturing (AM) processes to assess their suitability in the context of upper extremity splinting. Design/methodology/approach – This paper describes the design characteristics and subsequent fabrication of six different wrist splints using four different AM processes: laser sintering (LS), fused deposition modelling (FDM), stereolithography (SLA) and polyjet material jetting via Objet Connex. The suitability of each process was then compared against competing designs and processes from traditional splinting. The splints were created using a digital design workflow that combined recognised clinical best practice with design for AM principles. Findings – Research concluded that, based on currently available technology, FDM was considered the least suitable AM process for upper extremity splinting. LS, SLA and material jetting show promise for future applications, but further research and development into AM processes, materials and splint design optimisation is required if the full potential is to be realised. Originality/value – Unlike previous work that has applied AM processes to replicate traditional splint designs, the splints described are based on a digital design for AM workflow, incorporating novel features and physical properties not previously possible in clinical splinting. The benefits of AM for customised splint fabrication have been summarised. A range of AM processes have also been evaluated for splinting, exposing the limitations of existing technology, demonstrating novel and advantageous design features and opportunities for future research.

Efficient Process Planning Strategies for Additive Manufacturing

2017 ◽  
Author(s):  
Uppili Srinivasan Venkatesan ◽  
S. S. Pande
Keyword(s):  
Additive Manufacturing ◽  
Process Planning ◽  
Fitness Function ◽  
Performance Measure ◽  
Performance Parameters ◽  
Support Structures ◽  
Structure Generation ◽  
Part Quality ◽  
Material Utilization ◽  
Am Processes

This work reports the development of robust and efficient algorithms for optimum process planning of Additive Manufacturing (AM) processes needing support structures during fabrication. In particular, it addresses issues like part hollowing, support structure generation and optimum part orientation. Input to the system is a CAD model in STL format which is voxelized and hollowed using the 2D Hollowing strategy. A novel approach to design external as well as internal support structures for the hollowed model is developed considering the wall thickness and material properties. Optimum orientation of the hollowed part model is computed using Genetic Algorithm (GA). The Fitness Function for optimization is the weighted average of process performance parameters like build time, part quality and material utilization. A new performance measure has been proposed to choose the weightages for performance parameters to obtain overall optimum performance. The paper presents, in detail, the design and development of algorithms with results for typical case studies. The proposed methodology will significantly contribute to improving part quality, productivity and material utilization for AM processes.

Break It Down: Comparing the Effects of Lecture- and Module-Style Design for Additive Manufacturing Educational Interventions on Students’ Learning and Creativity

2021 ◽  
Author(s):  
Rohan Prabhu ◽  
Timothy W. Simpson ◽  
Scarlett R. Miller ◽  
Nicholas A. Meisel
Keyword(s):  
Additive Manufacturing ◽  
Educational Intervention ◽  
Self Efficacy ◽  
Educational Interventions ◽  
Evaluation Metrics ◽  
Single Session ◽  
Information Retention ◽  
Design Creativity ◽  
Am Processes ◽  
Design For Am

Abstract Given the growing presence of additive manufacturing (AM) processes in engineering design and manufacturing, there has emerged an increased interest in introducing AM and design for AM (DfAM) educational interventions in engineering education. Several researchers have proposed AM and DfAM educational interventions; however, some argue that these efforts might not be sufficient to develop higher-level skills among engineers (e.g., identifying design opportunities that leverage AM capabilities). Prior work has shown that longer, distributed educational interventions are more effective in encouraging learning and information retention; however, these interventions could also be time-consuming and expensive to implement. Therefore, there is a need to test the effectiveness of longer, distributed DfAM educational interventions compared to shorter, lecture-style interventions. Our aim in this research is to explore this research gap through an experimental study. Specifically, we compared two variations of a DfAM educational intervention: (1) a module-style intervention spread over two sessions with the introduction of DfAM evaluation metrics, and (2) a lecture-style intervention completed in a single session with no evaluation metrics introduced. From our results, we see that students who received the module-style intervention reported a greater increase in their DfAM self-efficacy. Additionally, students who received the module-style intervention reported having given a greater emphasis on part consolidation and feature size. Finally, we observe that the structure of the educational intervention did not influence the creativity of ideas generated by the participants. These findings highlight the utility of module-style DfAM educational interventions towards increasing DfAM self-efficacy, but not necessarily design creativity. Moreover, these findings highlight the need to formulate educational interventions that are effective and efficient.

Evaluation of Thermal Gelation of F-127 in a Non-Aqueous Solvent and its Suitability as a Support Material for Additive Manufacturing

2014 ◽  
Vol 911 ◽  
pp. 226-231 ◽  
Author(s):  
Muhammad Fahad ◽  
Maqsood Ahmed Khan ◽  
Marianne Gilbert
Keyword(s):  
Additive Manufacturing ◽  
Elevated Temperatures ◽  
Industrial Applications ◽  
Manufacturing Processes ◽  
Support Material ◽  
Support Materials ◽  
Thermal Gelation ◽  
Aqueous Solvent ◽  
Reverse Thermal Gel ◽  
Am Processes

Pluronics are well known for their reverse thermal gel (RTG) formation in aqueous solutions and have been used in a variety of industrial applications. Additive Manufacturing processes that utilize jetting technology require support materials for building parts that comprise holes, cavities and/or overhangs. Currently available support materials include waxes which due to their brittleness, are weak and can lead to accuracy issues during part building via jetting technology. Pluronic F-127 in a non-aqueous solvent (Formamide) have been investigated in this paper for thermal gelation at elevated temperatures and the suitability of this composition as support material for jetting based AM processes have been evaluated.

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