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.

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.

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 CONCEPTUAL DESIGN FOR ADDITIVE MANUFACTURING: AN EXPLORATIVE STUDY

2020 ◽  
Vol 1 ◽  
pp. 441-450
Author(s):  
F. Valjak ◽  
N. Bojčetić ◽  
A. Nordin ◽  
D. Godec
Keyword(s):  
Additive Manufacturing ◽  
Conceptual Design ◽  
Industrial Application ◽  
Future Trends ◽  
Design For Additive Manufacturing ◽  
Explorative Study ◽  
New Challenges ◽  
Design Workshop ◽  
Design For Am

AbstractWith the broader industrial application of Additive Manufacturing (AM), designers are facing new challenges in conceptual design for AM. To better understand the problematic, the authors organised a design workshop with six experts in AM. The paper presents the results of the conducted design workshop and discusses the current and future trends in research on the conceptual design for AM.

scholarly journals Hybrid Additive Manufacturing - Requirements Engineering Framework for Process Chain Considerations

2019 ◽  
Vol 1 (1) ◽  
pp. 3651-3660 ◽  
Author(s):  
Jan-Henrik Schneberger ◽  
Tobias Häfele ◽  
Jerome Kaspar ◽  
Michael Vielhaber
Keyword(s):  
Additive Manufacturing ◽  
Development Process ◽  
Functional Integration ◽  
Requirements Specification ◽  
Successful Implementation ◽  
Process Chain ◽  
Post Processing ◽  
Hybrid Processes ◽  
User Knowledge ◽  
Design Freedom

AbstractAdditive Manufacturing (AM) provides significant opportunities for design and functional integration of parts and assemblies. Compared to conventional processes, the AM principle increases design freedom notably. Additionally, numerous processible materials and hybrid processes enable the implementation in different industries, spanning from aerospace over automobile until medical applications.However, there are still handicaps to be addressed, arising from the large diversity of AM principles, post-processing and quality assurance issues, partly insufficient user knowledge, and organizational aspects. Coherently, lacking requirements specification hinders a successful consideration of AM in the early stages of development, and its later implementation.To promote knowledge build-up, this contribution presents a requirements specification framework, which supports developers in determining demands throughout the development process, including those resulting from post-processing and testing operations. By incorporating thorough analyses of general organizational and resort overarching limitations, this contribution promotes a successful implementation of suitable AM strategies.

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.

Multi-Objective Design Problem of Tire Wear and Visualization of Its Pareto Solutions2

2006 ◽  
Vol 34 (3) ◽  
pp. 170-194 ◽  
Author(s):  
M. Koishi ◽  
Z. Shida
Keyword(s):  
Inverse Problems ◽  
Conceptual Design ◽  
Dimensional Space ◽  
Design Stage ◽  
Objective Functions ◽  
Pareto Solutions ◽  
Design Problems ◽  
Multi Objective ◽  
Design Engineers ◽  
Design Variables

Abstract Since tires carry out many functions and many of them have tradeoffs, it is important to find the combination of design variables that satisfy well-balanced performance in conceptual design stage. To find a good design of tires is to solve the multi-objective design problems, i.e., inverse problems. However, due to the lack of suitable solution techniques, such problems are converted into a single-objective optimization problem before being solved. Therefore, it is difficult to find the Pareto solutions of multi-objective design problems of tires. Recently, multi-objective evolutionary algorithms have become popular in many fields to find the Pareto solutions. In this paper, we propose a design procedure to solve multi-objective design problems as the comprehensive solver of inverse problems. At first, a multi-objective genetic algorithm (MOGA) is employed to find the Pareto solutions of tire performance, which are in multi-dimensional space of objective functions. Response surface method is also used to evaluate objective functions in the optimization process and can reduce CPU time dramatically. In addition, a self-organizing map (SOM) proposed by Kohonen is used to map Pareto solutions from high-dimensional objective space onto two-dimensional space. Using SOM, design engineers see easily the Pareto solutions of tire performance and can find suitable design plans. The SOM can be considered as an inverse function that defines the relation between Pareto solutions and design variables. To demonstrate the procedure, tire tread design is conducted. The objective of design is to improve uneven wear and wear life for both the front tire and the rear tire of a passenger car. Wear performance is evaluated by finite element analysis (FEA). Response surface is obtained by the design of experiments and FEA. Using both MOGA and SOM, we obtain a map of Pareto solutions. We can find suitable design plans that satisfy well-balanced performance on the map called “multi-performance map.” It helps tire design engineers to make their decision in conceptual design stage.

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 Explicating concepts in reasoning from function to form by two-step innovative abductions

2016 ◽  
Vol 30 (2) ◽  
pp. 125-137 ◽  
Author(s):  
Ehud Kroll ◽  
Lauri Koskela
Keyword(s):  
Conceptual Design ◽  
Design Process ◽  
Abductive Reasoning ◽  
Parameter Analysis ◽  
Critical Examination ◽  
Functional Aspect ◽  
Specific Design ◽  
Design Processes ◽  
Step Process ◽  
Design Reasoning

AbstractThe mechanism of design reasoning from function to form is suggested to consist of a two-step inference of the innovative abduction type. First is an inference from a desired functional aspect to an idea, concept, or solution principle to satisfy the function. This is followed by a second innovative abduction, from the latest concept to form, structure, or mechanism. The intermediate entity in the logical reasoning, the concept, is thus made explicit, which is significant in following and understanding a specific design process, for educating designers, and to build a logic-based computational model of design. The idea of a two-step abductive reasoning process is developed from the critical examination of several propositions made by others. We use the notion of innovative abduction in design, as opposed to such abduction where the question is about selecting among known alternatives, and we adopt a previously proposed two-step process of abductive reasoning. However, our model is different in that the two abductions used follow the syllogistic pattern of innovative abduction. In addition to using a schematic example from the literature to demonstrate our derivation, we apply the model to an existing, empirically derived method of conceptual design called “parameter analysis” and use two examples of real design processes. The two synthetic steps of the method are shown to follow the proposed double innovative abduction scheme, and the design processes are presented as sequences of double abductions from function to concept and from concept to form, with a subsequent deductive evaluation step.

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