scholarly journals An optimisation framework for designs for additive manufacturing combining design, manufacturing and post-processing

2021 ◽  
Vol 27 (11) ◽  
pp. 90-105
Author(s):  
Anton Wiberg ◽  
Johan Persson ◽  
Johan Ölvander
Keyword(s):  
Additive Manufacturing ◽  
Design Methodology ◽  
Manufacturing Cost ◽  
Design For Additive Manufacturing ◽  
Post Processing ◽  
Process Selection ◽  
Content Type ◽  
Post Process ◽  
Alternative Designs

Purpose The purpose of this paper is to present a Design for Additive Manufacturing (DfAM) methodology that connects several methods, from geometrical design to post-process selection, into a common optimisation framework. Design/methodology/approach A design methodology is formulated and tested in a case study. The outcome of the case study is analysed by comparing the obtained results with alternative designs achieved by using other design methods. The design process in the case study and the potential of the method to be used in different settings are also discussed. Finally, the work is concluded by stating the main contribution of the paper and highlighting where further research is needed. Findings The proposed method is implemented in a novel framework which is applied to a physical component in the case study. The component is a structural aircraft part that was designed to minimise weight while respecting several static and fatigue structural load cases. An addition goal is to minimise the manufacturing cost. Designs optimised for manufacturing by two different AM machines (EOS M400 and Arcam Q20+), with and without post-processing (centrifugal finishing) are considered. The designs achieved in this study show a significant reduction in both weight and cost compared to one AM manufactured geometry designed using more conventional methods and one design milled in aluminium. Originality/value The method in this paper allows for the holistic design and optimisation of components while considering manufacturability, cost and component functionality. Within the same framework, designs optimised for different setups of AM machines and post-processing can be automatically evaluated without any additional manual work.

Maximizing design potential: investigating the effects of utilizing opportunistic and restrictive design for additive manufacturing in rapid response solutions

2021 ◽  
Vol ahead-of-print (ahead-of-print) ◽  
Author(s):  
Rohan Prabhu ◽  
Jordan Scott Masia ◽  
Joseph T. Berthel ◽  
Nicholas Alexander Meisel ◽  
Timothy W. Simpson
Keyword(s):  
Additive Manufacturing ◽  
Design Methodology ◽  
Linear Models ◽  
Design For Additive Manufacturing ◽  
Content Type ◽  
Manufacturing Efficiency ◽  
Material Usage ◽  
Build Time ◽  
Rapid Prototyping And Manufacturing ◽  
Design For Am

Purpose The COVID-19 pandemic has resulted in numerous innovative engineering design solutions, several of which leverage the rapid prototyping and manufacturing capabilities of additive manufacturing. This paper aims to study a subset of these solutions for their utilization of design for AM (DfAM) techniques and investigate the effects of DfAM utilization on the creativity and manufacturing efficiency of these solutions. Design/methodology/approach This study compiled 26 COVID-19-related solutions designed for AM spanning three categories: (1) face shields (N = 6), (2) face masks (N = 12) and (3) hands-free door openers (N = 8). These solutions were assessed for (1) DfAM utilization, (2) manufacturing efficiency and (3) creativity. The relationships between these assessments were then computed using generalized linear models to investigate the influence of DfAM utilization on manufacturing efficiency and creativity. Findings It is observed that (1) unique and original designs scored lower in their AM suitability, (2) solutions with higher complexity scored higher on usefulness and overall creativity and (3) solutions with higher complexity had higher build cost, build time and material usage. These findings highlight the need to account for both opportunistic and restrictive DfAM when evaluating solutions designed for AM. Balancing the two DfAM perspectives can support the development of solutions that are creative and consume fewer build resources. Originality/value DfAM evaluation tools primarily focus on AM limitations to help designers avoid build failures. This paper proposes the need to assess designs for both, their opportunistic and restrictive DfAM utilization to appropriately assess the manufacturing efficiency of designs and to realize the creative potential of adopting AM.

Additive manufacturing a powerful tool for the aerospace industry

2021 ◽  
Vol ahead-of-print (ahead-of-print) ◽  
Author(s):  
Mahyar Khorasani ◽  
AmirHossein Ghasemi ◽  
Bernard Rolfe ◽  
Ian Gibson
Keyword(s):  
Additive Manufacturing ◽  
Rapid Prototyping ◽  
Production Costs ◽  
Process Chain ◽  
Post Processing ◽  
Jet Engine ◽  
Content Type ◽  
Support Optimization ◽  
The Cost

Purpose Additive manufacturing (AM) offers potential solutions when conventional manufacturing reaches its technological limits. These include a high degree of design freedom, lightweight design, functional integration and rapid prototyping. In this paper, the authors show how AM can be implemented not only for prototyping but also production using different optimization approaches in design including topology optimization, support optimization and selection of part orientation and part consolidation. This paper aims to present how AM can reduce the production cost of complex components such as jet engine air manifold by optimizing the design. This case study also identifies a detailed feasibility analysis of the cost model for an air manifold of an Airbus jet engine using various strategies, such as computer numerical control machining, printing with standard support structures and support optimization. Design/methodology/approach Parameters that affect the production price of the air manifold such as machining, printing (process), feedstock, labor and post-processing costs were calculated and compared to find the best manufacturing strategy. Findings Results showed that AM can solve a range of problems and improve production by customization, rapid prototyping and geometrical freedom. This case study showed that 49%–58% of the cost is related to pre- and post-processing when using laser-based powder bed fusion to produce the air manifold. However, the cost of pre- and post-processing when using machining is 32%–35% of the total production costs. The results of this research can assist successful enterprises, such as aerospace, automotive and medical, in successfully turning toward AM technology. Originality/value Important factors such as validity, feasibility and limitations, pre-processing and monitoring, are discussed to show how a process chain can be controlled and run efficiently. Reproducibility of the process chain is debated to ensure the quality of mass production lines. Post-processing and qualification of the AM parts are also discussed to show how to satisfy the demands on standards (for surface quality and dimensional accuracy), safety, quality and certification. The original contribution of this paper is identifying the main production costs of complex components using both conventional and AM.

Design for additive manufacturing: a comprehensive review of the tendencies and limitations of methodologies

2021 ◽  
Vol ahead-of-print (ahead-of-print) ◽  
Author(s):  
Luis Lisandro Lopez Taborda ◽  
Heriberto Maury ◽  
Jovanny Pacheco
Keyword(s):  
Additive Manufacturing ◽  
Design Methodology ◽  
Functional Performance ◽  
Cost Evaluation ◽  
Product Management ◽  
Design For Additive Manufacturing ◽  
Content Type ◽  
Starting Point ◽  
The Subject ◽  
Future Work

Purpose There are many investigations in design methodologies, but there are also divergences and convergences as there are so many points of view. This study aims to evaluate to corroborate and deepen other researchers’ findings, dissipate divergences and provide directing to future work on the subject from a methodological and convergent perspective. Design/methodology/approach This study analyzes the previous reviews (about 15 reviews) and based on the consensus and the classifications provided by these authors, a significant sample of research is analyzed in the design for additive manufacturing (DFAM) theme (approximately 80 articles until June of 2017 and approximately 280–300 articles until February of 2019) through descriptive statistics, to corroborate and deepen the findings of other researchers. Findings Throughout this work, this paper found statistics indicating that the main areas studied are: multiple objective optimizations, execution of the design, general DFAM and DFAM for functional performance. Among the main conclusions: there is a lack of innovation in the products developed with the methodologies, there is a lack of exhaustivity in the methodologies, there are few efforts to include environmental aspects in the methodologies, many of the methods include economic and cost evaluation, but are not very explicit and broad (sustainability evaluation), it is necessary to consider a greater variety of functions, among other conclusions Originality/value The novelty in this study is the methodology. It is very objective, comprehensive and quantitative. The starting point is not the case studies nor the qualitative criteria, but the figures and quantities of methodologies. The main contribution of this review article is to guide future work on the subject from a methodological and convergent perspective and this article provides a broad database with articles containing information on many issues to make decisions: design methodology; optimization; processes, selection of parts and materials; cost and product management; mechanical, electrical and thermal properties; health and environmental impact, etc.

Aircraft part substitution via additive manufacturing: design, simulation, fabrication and testing

2021 ◽  
Vol ahead-of-print (ahead-of-print) ◽  
Author(s):  
Alberto Boschetto ◽  
Luana Bottini ◽  
Valerio Cardini ◽  
Marco Eugeni ◽  
Paolo Gaudenzi ◽  
...  
Keyword(s):  
Additive Manufacturing ◽  
Design Methodology ◽  
Batch Size ◽  
Production Volume ◽  
Process Step ◽  
Content Type ◽  
Integrated Approaches ◽  
Traditional Manufacturing ◽  
Practical Implications

Purpose This paper aims to provide a case study focused on the substitution through selective laser melting of a part typically fabricated by traditional manufacturing. Design/methodology/approach To exploit the additive manufacturing (AM) advantages, the retrieving of the reconfiguration part data was provided, the process strategies by means of the interchange file handling and pre and post-processing were investigated and a re-design of the part was developed. Finally, the fabricated part was tested and analyzed. Findings Results claimed that a reconfiguration of the manufacturing framework plays an important role at each step of the process otherwise many AM benefits can be lost. In the paper, a set of recommendations, suggestions and hints regarding the implementation of AM for part substitutions is provided. Research limitations/implications Many aspects of the AM adoption, such as the production cost, energy consumption, sustainability and production volume, depend upon the geometry, batch size and other impactful factors, and thus they need to be studied in a case-by-case manner. Practical implications The proposed approaches have the concrete aim to address industrial resources toward the maximization of AM benefits in part substituting. Originality/value In this paper, the substitution of a part is fully undertaken from the early data collection to the manufactured part testing providing integrated approaches for each process step.

scholarly journals A design for additive manufacturing case study: fingerprint stool on a BigRep ONE

2019 ◽  
Vol 25 (6) ◽  
pp. 1069-1079 ◽  
Author(s):  
James I. Novak ◽  
Jonathon O’Neill
Keyword(s):  
Additive Manufacturing ◽  
Large Scale ◽  
Future Research ◽  
Design For Additive Manufacturing ◽  
Fused Filament Fabrication ◽  
Content Type ◽  
Layer Height ◽  
Design Engineers ◽  
Final Design

Purpose This paper aims to present new qualitative and quantitative data about the recently released “BigRep ONE” 3 D printer led by the design of a one-off customized stool. Design/methodology/approach A design for additive manufacturing (DfAM) framework was adopted, with simulation data iteratively informing the final design. Findings Process parameters can vary manufacturing costs of a stool by over AU$1,000 and vary print time by over 100 h. Following simulation, designers can use the knowledge to inform iteration, with a second variation of the design being approximately 50 per cent cheaper and approximately 50 per cent faster to manufacture. Metrology data reveal a tolerance = 0.342 per cent in overall dimensions, and surface roughness data are presented for a 0.5 mm layer height. Research limitations/implications Led by design, this study did not seek to explore the full gamut of settings available in slicing software, focusing predominantly on nozzle diameter, layer height and number of walls alongside the recommended settings from BigRep. The study reveals numerous areas for future research, including more technical studies. Practical implications When knowledge and techniques from desktop 3 D printing are scaled up to dimensions measuring in meters, new opportunities and challenges are presented for design engineers. Print times and material costs in particular are scaled up significantly, and this study provides numerous considerations for research centers, 3 D printing bureaus and manufacturers considering large-scale fused filament fabrication manufacturing. Originality/value This is the first peer-reviewed study involving the BigRep ONE, and new knowledge is presented about the practical application of the printer through a design-led project. Important relationships between material volume/cost and print time are valuable for early adopters.

Towards a taxonomy of intergenerational knowledge transfer practices

2018 ◽  
Vol 25 (2) ◽  
pp. 81-91
Author(s):  
Kerstin Kuyken ◽  
Mehran Ebrahimi ◽  
Anne-Laure Saives
Keyword(s):  
Knowledge Transfer ◽  
Comparative Study ◽  
Design Methodology ◽  
Qualitative Case Study ◽  
High Tech ◽  
Content Type ◽  
Case Study Design ◽  
Younger Workers ◽  
Intergenerational Knowledge

Purpose This paper aims to develop a better understanding of intergenerational knowledge transfer (IKT) practices by adopting a context-related and comparative perspective. Design/methodology/approach A qualitative case study design involving 83 interviews and non-participative observation in German and Quebec organizations has been chosen. Findings Two distinctive archetypes of IKT emerge from both national contexts: “we-individualizing” (Germany) and “I-connecting” (Quebec), leading to an eightfold taxonomy of IKT practices. Research limitations/implications This research is limited to young and senior workers and to high-tech sectors. Originality/value Comparative and inductive study of IKT, adaptation of IKT practices to national contexts, retaining younger workers. This inductive and comparative study allows a better adaptation of IKT practices to national contexts and therefore a better retention of younger workers.

Digital forensics and evolving cyber law: case of BIMSTEC countries

2019 ◽  
Vol 22 (4) ◽  
pp. 744-752
Author(s):  
Sisira Dharmasri Jayasekara ◽  
Iroshini Abeysekara
Keyword(s):  
Information Technology ◽  
Design Methodology ◽  
Digital Forensics ◽  
Content Type ◽  
Global Context ◽  
Study Approach ◽  
Legal Frameworks ◽  
Work Done

Purpose The purpose of this paper is to discuss the role of digital forensics in an evolving environment of cyber laws giving attention to Bay of Bengal Initiative for Multi-Sectoral Technical and Economic Cooperation (BIMSTEC) countries, comprising Bangladesh, India, Myanmar, Sri Lanka, Thailand, Nepal and Bhutan, in a dynamic global context. Design/methodology/approach This study uses a case study approach to discuss the digital forensics and cyber laws of BIMSTEC countries. The objective of the study was expected to be achieved by referring to decided cases in different jurisdictions. Cyber laws of BIMSTEC countries were studied for the purpose of this study. Findings The analysis revealed that BIMSTEC countries are required to amend legislation to support the growth of information technology. Most of the legislation are 10-15 years old and have not been amended to resolve issues on cyber jurisdictions. Research limitations/implications This study was limited to the members of the BIMSTEC. Originality/value This paper is an original work done by the authors who have discussed the issues of conducting investigations with respect to digital crimes in a rapidly changing environment of information technology and deficient legal frameworks.

scholarly journals Exploring producers' motivations and challenges within a farmers' market

2020 ◽  
Vol 122 (7) ◽  
pp. 2089-2103
Author(s):  
Rosario Michel-Villarreal ◽  
Eliseo Luis Vilalta-Perdomo ◽  
Martin Hingley
Keyword(s):  
Design Methodology ◽  
Farmers Markets ◽  
Full Time ◽  
Structured Interviews ◽  
Farmers Market ◽  
Content Type ◽  
Food Supply Chains ◽  
Part Time ◽  
Short Food Supply Chains

PurposeThe purpose of this study is to explore food producers' motivations and challenges whilst participating in short food supply chains (SFSCs). This paper compares findings with previous literature and investigates the topic in the context of producers' motivations.Design/methodology/approachThe paper includes a literature review concerning producers' motivations to engage in SFSCs. A case study was designed to investigate motivations underlying producers' engagement in SFSCs, as well as the challenges that they face. Semi-structured interviews were conducted in a farmers' market located in Mexico. Thematic analysis is used to identify the principal issues for producers'. Propositions based on findings are presented.FindingsFindings suggest that small, large, part-time and full-time producers are willing to engage with farmers' markets for diverse primary economic and non-economic motivations. Individual and collective challenges were also identified.Originality/valueThis research helps to explain producers' motivations and challenges within SFSCs in an under-researched context, namely a focus on producers' and in the Global South.

Is culture change a fad? Driving business results at Penna, ten years on

2014 ◽  
Vol 13 (3) ◽  
pp. 123-126
Author(s):  
Bev White ◽  
Gary Browning ◽  
Javier Bajer
Keyword(s):  
Culture Change ◽  
Design Methodology ◽  
Organizational Context ◽  
Longitudinal Case Study ◽  
Content Type ◽  
Business Results ◽  
Sustainable Culture ◽  
Systemic Interventions ◽  
Successful Business

Purpose – Ten years ago Penna, the global HR services group, needed a radical business and culture re-invention if it was to survive. This article aims to tell the story behind Penna's journey and describe how a sustainable culture change intervention became the cornerstone of a successful business. Design/methodology/approach – This case study is the result of an initial ethnographical research followed by concrete and systemic interventions. Findings – The case study identifies four elements that sustained the business impact of a culture change program over a significant period of time. Originality/value – This longitudinal case study follows a culture change program in an organizational context over a period of ten years.

Building insurance through an NGO

2016 ◽  
Vol 76 (1) ◽  
pp. 119-139 ◽  
Author(s):  
Marie-Christine Bélanger
Keyword(s):  
Design Methodology ◽  
Smallholder Farmers ◽  
Crop Insurance ◽  
Specific Training ◽  
Close Collaboration ◽  
Agricultural Insurance ◽  
Content Type ◽  
Level Of Education ◽  
Challenges And Opportunities

Purpose – This paper is based on a crop insurance implementation currently undergoing in Haiti. The purpose of this paper is to present the development of a program tailored to rice production in the Artibonite Valley, the challenges and opportunities that are arising from the exercise as well as pitfalls and ways to avoid them. Design/methodology/approach – The Système de Financement et d’Assurances Agricoles en Haïti’s approach for the development of crop insurance is in accordance with 13 concepts considered essential in the implementation of agricultural insurance programs. The case study is presented through each of these 13 fundamental concepts. Findings – The paper provides an insight on challenges any organization will face when implementing crop insurance for smallholder farmers. It points out notably that close collaboration of executing agencies with local partners is essential from data collection through insurance development and delivery and that all participants should receive a specific training tailored to their level of education and understanding. Social implications – Haiti is one of the poorest countries on the planet. Smallholder farmers could benefit a lot from crop insurance. It could help them stabilize their income when facing crop losses due to natural hazards or uncontrollable natural events. Originality/value – This paper fulfills an identified need to share real case studies exposing challenges faced when implementing crop insurance for smallholder farmers.

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