scholarly journals A Part Consolidation Design Method for Additive Manufacturing based on Product Disassembly Complexity

2020 ◽  
Vol 10 (3) ◽  
pp. 1100 ◽  
Author(s):  
Samyeon Kim ◽  
Seung Ki Moon
Keyword(s):  
Additive Manufacturing ◽  
End Of Life ◽  
Design Method ◽  
Life Stage ◽  
Product Recovery ◽  
Manufacturing Constraints ◽  
Part Consolidation ◽  
Product Disassembly ◽  
Part Complexity ◽  
Manufacturing Stage

Parts with complex geometry have been divided into multiple parts due to manufacturing constraints of conventional manufacturing. However, since additive manufacturing (AM) is able to fabricate 3D objects in a layer-by-layer manner, design for AM has been researched to explore AM design benefits and alleviate manufacturing constraints of AM. To explore more AM design benefits, part consolidation has been researched for consolidating multiple parts into fewer number of parts at the manufacturing stage of product lifecycle. However, these studies have been less considered product recovery and maintenance at end-of-life stage. Consolidated parts for the manufacturing stage would not be beneficial at end-of-life stage and lead to unnecessary waste of materials during maintenance. Therefore, in this research, a design method is proposed to consolidate parts for considering maintenance and product recovery at the end-of-life stage by extending a modular identification method. Single part complexity index (SCCI) is introduced to measure part and interface complexities simultaneously. Parts with high SCCI values are grouped into modules that are candidates for part consolidation. Then the product disassembly complexity (PDC) can be used to measure disassembly complexity of a product before and after part consolidation. A case study is performed to demonstrate the usefulness of the proposed design method. The proposed method contributes to guiding how to consolidate parts for enhancing product recovery.

Assessing and Generating Modules for Product Recovery

2015 ◽  
Author(s):  
Samyeon Kim ◽  
Seung Ki Moon
Keyword(s):  
Product Design ◽  
End Of Life ◽  
Interface Design ◽  
Life Stage ◽  
New Products ◽  
Design Guidelines ◽  
Product Recovery ◽  
Negative Effects ◽  
Design Guideline ◽  
Modular Product

As technology pushes customers to buy new released products, especially mobile phone, high product replacement from the customers plays a role in increasing production rate for new products and rate of abandoned products. It accelerates environmental degradation like natural resource usage for the new products and pollutions generated by disposing the abandoned products. In this respect, product recovery is needed to reduce landfill rates, and resource usages, and prolong product lifecycle. Modular drivers such as interface design, material type, and components’ lifespan are applied to design modules for product recovery. The objective of this research is to support designers to assess initial modules and then reorganize modules for product recovery. First, according to conventional modular product design, the initial modules are generated. Then, since it is difficult to estimate how much the modules have negative effects on environment, the environmental impacts of a product are assessed by Eco-Indicator 99 based on used materials. Also, the complexity of the interface design is measured to understand how the modules are easily disassembled for upgrading and maintaining end-of-life products by using weighted-modular complexity score (wMCS). After assessing the product based on the Eco-Indicator 99 and wMCS, we apply new design guidelines to improve sustainability of a product in the end of life stage. Consequently, we compare the extent to design for sustainability before and after redesigning a product based on the design guideline. To demonstrate the effectiveness of the modular product design, we carry out a case study with a coffee maker.

scholarly journals Design for Additive Manufacturing: A Systematic Review

2020 ◽  
Vol 12 (19) ◽  
pp. 7936 ◽  
Author(s):  
Abdullah Alfaify ◽  
Mustafa Saleh ◽  
Fawaz M. Abdullah ◽  
Abdulrahman M. Al-Ahmari
Keyword(s):  
Additive Manufacturing ◽  
Review Paper ◽  
Waste Minimization ◽  
Design For Additive Manufacturing ◽  
Great Flexibility ◽  
Sustainable Products ◽  
Novel Method ◽  
Part Consolidation ◽  
Method Of Production ◽  
Part Complexity

The last few decades have seen rapid growth in additive manufacturing (AM) technologies. AM has implemented a novel method of production in design, manufacture, and delivery to end-users. Accordingly, AM technologies have given great flexibility in design for building complex components, highly customized products, effective waste minimization, high material variety, and sustainable products. This review paper addresses the evolution of engineering design to take advantage of the opportunities provided by AM and its applications. It discusses issues related to the design of cellular and support structures, build orientation, part consolidation and assembly, materials, part complexity, and product sustainability.

Sustainable Product Design by a Simultaneous Consideration of Pre-Life and End-of-Life of Products

2009 ◽  
Author(s):  
Minjung Kwak ◽  
Harrison M. Kim
Keyword(s):  
Product Design ◽  
End Of Life ◽  
Life Stage ◽  
Product Recovery ◽  
Design Stage ◽  
Manufacturing Companies ◽  
Sustainable Product Design ◽  
Recovery Method ◽  
Recovery Potential ◽  
Sustainable Product

Product recovery has become a field of rapidly growing interest for product manufacturers as a promising solution for product stewardship as well as economic viability. As product recovery is a process highly dependent upon the way a product is designed, it should be considered early at the design stage so that the product may be designed to facilitate efficient and effective recovery at its end-of-life stage. To make a product easy to recover, manufacturing companies first need to understand the links between product design and recovery profit. They should be able to evaluate which design is better than others and why that is so. To accommodate such companies that seek for a design-for-recovery method, in this paper, a comparative study is conducted to analyze how design differences affect product recovery and what architecture characteristics are desirable from the end-of-life perspective. Three cell phone handset designs sharing the same design concept but entailing different architecture are created, for which the individual designs and the recovery potential of each design are evaluated under three different scenarios. The results highlight preferred design alternatives with their design implications for sustainable product design.

Palliative care for end-of-life stage in oncologic disease

2018 ◽  
Vol 4 (45) ◽  
pp. 27
Author(s):  
Lucian MIRON ◽  
Alexandru C. Grigorescu
Keyword(s):  
Palliative Care ◽  
End Of Life ◽  
Life Stage

scholarly journals Design of a Variable-Stiffness Compliant Skin for a Morphing Leading Edge

2021 ◽  
Vol 11 (7) ◽  
pp. 3165
Author(s):  
Zhigang Wang ◽  
Yu Yang
Keyword(s):  
Composite Laminate ◽  
Large Scale ◽  
Design Method ◽  
Leading Edge ◽  
Variable Stiffness ◽  
Manufacturing Constraints ◽  
Aircraft Wing ◽  
Noise Abatement ◽  
Civil Aircraft ◽  
Final Profile

A seamless and smooth morphing leading edge has remarkable potential for noise abatement and drag reduction of civil aircraft. Variable-stiffness compliant skin based on tailored composite laminate is a concept with great potential for morphing leading edge, but the currently proposed methods have difficulty in taking the manufacturing constraints or layup sequence into account during the optimization process. This paper proposes an innovative two-step design method for a variable-stiffness compliant skin of a morphing leading edge, which includes layup optimization and layup adjustment. The combination of these two steps can not only improve the deformation accuracy of the final profile of the compliant skin but also easily and effectively determine the layup sequence of the composite layup. With the design framework, an optimization model is created for a variable-stiffness compliant skin, and an adjustment method for its layups is presented. Finally, the deformed profiles between the directly optimized layups and the adjusted ones are compared to verify its morphing ability and accuracy. The final results demonstrate that the obtained deforming ability and accuracy are suitable for a large-scale aircraft wing.

scholarly journals A Shape Optimization Method for Part Design Derived from the Buildability Restrictions of the Directed Energy Deposition Additive Manufacturing Process

Designs ◽  
2020 ◽  
Vol 4 (3) ◽  
pp. 19
Author(s):  
Andreas K. Lianos ◽  
Harry Bikas ◽  
Panagiotis Stavropoulos
Keyword(s):  
Topology Optimization ◽  
Additive Manufacturing ◽  
Energy Deposition ◽  
Design Method ◽  
Current Trend ◽  
Internal Stresses ◽  
Material Distribution ◽  
Load Case ◽  
Design Elements ◽  
Industrial Sectors

The design methodologies and part shape algorithms for additive manufacturing (AM) are rapidly growing fields, proven to be of critical importance for the uptake of additive manufacturing of parts with enhanced performance in all major industrial sectors. The current trend for part design is a computationally driven approach where the parts are algorithmically morphed to meet the functional requirements with optimized performance in terms of material distribution. However, the manufacturability restrictions of AM processes are not considered at the primary design phases but at a later post-morphed stage of the part’s design. This paper proposes an AM design method to ensure: (1) optimized material distribution based on the load case and (2) the part’s manufacturability. The buildability restrictions from the direct energy deposition (DED) AM technology were used as input to the AM shaping algorithm to grant high AM manufacturability. The first step of this work was to define the term of AM manufacturability, its effect on AM production, and to propose a framework to estimate the quantified value of AM manufacturability for the given part design. Moreover, an AM design method is proposed, based on the developed internal stresses of the build volume for the load case. Stress tensors are used for the determination of the build orientation and as input for the part morphing. A top-down mesoscale geometric optimization is used to realize the AM part design. The DED Design for Additive Manufacturing (DfAM) rules are used to delimitate the morphing of the part, representing at the same time the freeform mindset of the AM technology. The morphed shape of the part is optimized in terms of topology and AM manufacturability. The topology optimization and AM manufacturability indicator (TMI) is introduced to screen the percentage of design elements that serve topology optimization and the ones that serve AM manufacturability. In the end, a case study for proof of concept is realized.

scholarly journals Modelling, Design and Validation of a Parallel Kinematic Robot for Additive Manufacture Applications

2021 ◽  
pp. 019-029
Author(s):  
Lahoud Marcel ◽  
Melendez Leonardo ◽  
Gil Arturo
Keyword(s):  
Additive Manufacturing ◽  
Open Source Software ◽  
Design Method ◽  
Kinematic Model ◽  
Additive Manufacture ◽  
Parallel Kinematics ◽  
Cartesian Space ◽  
Parallel Kinematic ◽  
Manufacturing Applications ◽  
Design Construction

The additive manufacture is a fabrication process that has taken huge steps in the last decade, even though the first researches and prototypes are around since almost forty years ago. In this article, a design method for a Parallel Kinematics Robot for Additive Manufacturing Applications is proposed. A numerical model is obtained from the kinematics of the robot for which the design, construction and assembly are planned using recycled materials and equipment. The control of the robot is done using open source software, allowing the planning of trajectories in the Cartesian space on a maximum designed cylindrical workspace of 300mm in diameter by 300mm high. At the end of the work the robot was identified, the kinematic model was validated and considerations for future works were given.

An improved lattice structure design optimization framework considering additive manufacturing constraints

2017 ◽  
Vol 23 (2) ◽  
pp. 305-319 ◽  
Author(s):  
Recep M. Gorguluarslan ◽  
Umesh N. Gandhi ◽  
Yuyang Song ◽  
Seung-Kyum Choi
Keyword(s):  
Additive Manufacturing ◽  
Lattice Structure ◽  
Structure Optimization ◽  
Optimization Methods ◽  
Structure Design ◽  
Second Phase ◽  
Manufacturing Constraints ◽  
Ground Structure ◽  
Content Type ◽  
Optimization Framework

Purpose Methods to optimize lattice structure design, such as ground structure optimization, have been shown to be useful when generating efficient design concepts with complex truss-like cellular structures. Unfortunately, designs suggested by lattice structure optimization methods are often infeasible because the obtained cross-sectional parameter values cannot be fabricated by additive manufacturing (AM) processes, and it is often very difficult to transform a design proposal into one that can be additively designed. This paper aims to propose an improved, two-phase lattice structure optimization framework that considers manufacturing constraints for the AM process. Design/methodology/approach The proposed framework uses a conventional ground structure optimization method in the first phase. In the second phase, the results from the ground structure optimization are modified according to the pre-determined manufacturing constraints using a second optimization procedure. To decrease the computational cost of the optimization process, an efficient gradient-based optimization algorithm, namely, the method of feasible directions (MFDs), is integrated into this framework. The developed framework is applied to three different design examples. The efficacy of the framework is compared to that of existing lattice structure optimization methods. Findings The proposed optimization framework provided designs more efficiently and with better performance than the existing optimization methods. Practical implications The proposed framework can be used effectively for optimizing complex lattice-based structures. Originality/value An improved optimization framework that efficiently considers the AM constraints was reported for the design of lattice-based structures.

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