Design Innovation Incorporating Additive Manufacturing: Creation and Assessment of a Design Tool

2021 ◽  
Author(s):  
Daniel Jensen ◽  
Mark Menefee ◽  
Mahesh Pokharel ◽  
Brian Kaplun ◽  
Kristin Wood ◽  
...  
Keyword(s):  
Additive Manufacturing ◽  
Design Tool ◽  
Design Innovation

Design Innovation Incorporating Additive Manufacturing: Creation and Assessment of a Design Tool

2020 ◽  
Author(s):  
Mark Menefee ◽  
Mahesh Pokharel ◽  
Brian Kaplun ◽  
Daniel Jensen ◽  
Christopher Yakacki ◽  
...  
Keyword(s):  
Additive Manufacturing ◽  
Assessment Tool ◽  
Deep Understanding ◽  
Design Tool ◽  
Space Applications ◽  
Design Assessment ◽  
Design Processes ◽  
Design Heuristics ◽  
Design Engineers ◽  
Design Innovation

Abstract Additive Manufacturing (AM) offers design engineers new and advanced manufacturing processes to consider when developing new products or redesigning and evolving current products. AM includes 3D printing processes to quickly produce complex parts and prototypes, that were previously uneconomical or impossible to fabricate. Engineers and organizations have an increasing need to incorporate AM as part of product development; however, design heuristics, design methodologies, and design tools to support AM are nascent and only recently emerging. To enhance Design for Additive Manufacturing (DfAM), this research seeks to develop an accessible, computer-based design assistant that will aid designers in incorporating AM into their design processes. The design assistant implements a distinctive and user-centered Design Innovation (DI) process, set of methods, and set of principles based on a 4D design framework. This 4D framework encompasses the UK Design Council’s double diamond model and includes the phases of Discover, Define, Develop, and Deliver. The Discover phase entails user studies and a deep understanding and empathy for the user. The Define phase considers the reframing of design opportunities based on derived insights from the modeling users’ interactions. The Develop phase uses a variety of methods to create a large quantity of innovative ideas and concepts, and the Deliver phase implements a set of methods to prototype, test, pitch, and ultimately produce deliverables for a market or community. We demonstrate the design assistant tool for AM through the development of high-end bracket design for space applications. The design considers the Selective Laser Melting (SLM) process for productions and incorporated topology optimization approaches. This demonstrative case study shows how the tool includes design heuristics and approaches for each of the 4-Ds that assist designers in implementing AM capabilities as part of repeatable design processes. Assessment of the tool is carried out through systematic assessments performed by practicing design engineers that have knowledge of AM. Initial results show that the design assessment tool is very helpful when designers consider using AM and also in helping them use AM in effective and efficient manners.

Reconfigurable molds and a fabrication-aware design tool for manufacturing concrete grid structures

2021 ◽  
pp. 147807712110300
Author(s):  
Ali Baghi ◽  
Saleh Kalantari ◽  
Aryan Baghi
Keyword(s):  
Additive Manufacturing ◽  
Casting Machine ◽  
Design Tool ◽  
Digital Design ◽  
Architectural Geometry ◽  
Current Trends ◽  
Design And Manufacturing ◽  
Concrete Joints ◽  
Concrete Casting ◽  
Concrete Elements

The design and manufacturing of concrete elements need to be reconsidered in light of current trends in architectural geometry. Today, there is a movement toward greater customization and adaptability of concrete elements using “reconfigurable formworks” and “additive manufacturing.” Our study approached the issue of fabricating non-standardized concrete elements from the perspective of a “reconfigurable fabrication platform.” Specifically, we developed a method of fabricating geometrically diverse concrete joints by combining flexible pressure-enduring tubes with a rigid mechanism, resulting in an adaptive concrete-casting machine. This platform, which we named “Flexi-node,” can be used in conjunction with a relevant fabrication-aware digital design tool. Users can computationally design and fabricate a great variety of concrete joints using just one mold, with a minimum of material waste and with no distortion from hydrostatic pressure as would typically occur in a fully flexible formwork.

scholarly journals Design for Additive Manufacturing: Optimization of Piping Network in Compact System With Enhanced Path-Finding Approach

2018 ◽  
Vol 140 (8) ◽  
Author(s):  
Pei Cao ◽  
Zhaoyan Fan ◽  
Robert X. Gao ◽  
J. Tang
Keyword(s):  
Additive Manufacturing ◽  
Video Game ◽  
Optimal Path ◽  
Computational Cost ◽  
Design Tool ◽  
Computational Time ◽  
Path Finding ◽  
Network Systems ◽  
Efficient Manner ◽  
Visibility Graphs

This research aims at unleashing the potential of additive manufacturing technology in industrial design that can produce structures/devices with irregular component geometries to reduce sizes/weights. We explore, by means of path-finding, the length minimization of freeform hydraulic piping network in compact space under given constraints. Previous studies on path-finding have mainly focused on enhancing computational efficiency due to the need to produce rapid results in such as navigation and video-game applications. In this research, we develop a new Focal Any-Angle A* approach that combines the merits of grid-based method and visibility graph-based method. Specifically, we formulate pruned visibility graphs preserving only the useful portion of the vertices and then find the optimal path based on the candidate vertices using A*. The reduced visibility graphs enable us to outperform approximations and maintain the optimality of exact algorithms in a more efficient manner. The algorithm proposed is compared to the traditional A* on Grids, Theta* and A* on visibility graphs in terms of path length, number of nodes evaluated, as well as computational time. As demonstrated and validated through case studies, the proposed method is capable of finding the shortest path with tractable computational cost, which provides a viable design tool for the additive manufacturing of piping network systems.

scholarly journals A design tool for resource-efficient fabrication of 3d-graded structural building components using additive manufacturing

2017 ◽  
Vol 82 ◽  
pp. 75-83 ◽  
Author(s):  
F. Craveiro ◽  
H.M. Bartolo ◽  
A. Gale ◽  
J.P. Duarte ◽  
P.J. Bartolo
Keyword(s):  
Additive Manufacturing ◽  
Design Tool ◽  
Building Components

scholarly journals Guidelines for Topology Optimization as Concept Design Tool and Their Application for the Mechanical Design of the Inner Frame to Support an Ancient Bronze Statue

2021 ◽  
Vol 11 (17) ◽  
pp. 7834
Author(s):  
Abas Ahmad ◽  
Michele Bici ◽  
Francesca Campana
Keyword(s):  
Topology Optimization ◽  
Additive Manufacturing ◽  
Early Stage ◽  
Lightweight Design ◽  
Design Tool ◽  
Design Solution ◽  
Design Activity ◽  
Concept Design ◽  
Bronze Statue ◽  
Design Requirements

For the past few decades, topology optimization (TO) has been used as a structural design optimization tool. With the passage of time, this kind of usage of TO has been extended to many application fields and branches, thanks to a better understanding of how manufacturing constraints can achieve a practical design solution. In addition, the advent of additive manufacturing and its subsequent advancements have further increased the applications of TO, raising the chance of competitive manufacturing. Design for additive manufacturing has also promoted the adoption of TO as a concept design tool of structural components. Nevertheless, the most frequent applications are related to lightweight design with or without design for assembly. A general approach to integrate TO in concept designs is still missing. This paper aims to close this gap by proposing guidelines to translate design requirements into TO inputs and to include topology and structural concerns at the early stage of design activity. Guidelines have been applied for the concept design of an inner supporting frame of an ancient bronze statue, with several constraints related to different general design requirements, i.e., lightweight design, minimum displacement, and protection of the statue’s structural weak zones to preserve its structural integrity. Starting from the critical analysis of the list of requirements, a set of concepts is defined through the application of TO with different set-ups (loads, boundary conditions, design and non-design space) and ranked by the main requirements. Finally, a validation of the proposed approach is discussed comparing the achieved results with the ones carried out through a standard iterative concept design.

Design Innovation With Additive Manufacturing: A Methodology

2019 ◽  
Author(s):  
K. Blake Perez ◽  
Carlye A. Lauff ◽  
Bradley A. Camburn ◽  
Kristin L. Wood
Keyword(s):  
Additive Manufacturing ◽  
Design Process ◽  
Business Models ◽  
Engineering Product ◽  
Process Framework ◽  
New Business ◽  
Design Innovation ◽  
End Use ◽  
New Business Models

Abstract Additive manufacturing (AM) has matured rapidly in the past decade and has made significant progress towards a reliable and repeatable manufacturing process. The technology opens the doors for new types of innovation in engineering product development. However, there exists a need for a design process framework to efficiently and effectively explore these newly enabled design spaces. Significant work has been done to understand how to make existing products and components additively manufacturable, yet there still exists an opportunity to understand how AM can be leveraged from the very outset of the design process. Beyond end use products, AM-enabled opportunities include an enhanced design process using AM, new business models enabled by AM, and the production of new AM technologies. In this work, we propose the use, adaptation and evolution of the SUTD-MIT International Design Centre’s Design Innovation (DI) framework to assist organizations effectively explore all of these AM opportunities in an efficient and guided manner. We build on prior work that extracted and formalized design principles for AM. This paper discusses the creation and adaptation of the Design Innovation with Additive Manufacturing (DIwAM) methodology, through the combination of these principles and methods under the DI framework to better identify and realize new innovations enabled by AM. The paper concludes with a representative case study with industry that employs the DIwAM framework and the outcomes of that project. Future studies will analyze the effects that DIwAM has on designers, projects, and solutions.

Topology Optimization for Additive Manufacturing Considering Layer-Based Minimum Feature Sizes

2017 ◽  
Author(s):  
Mikhail Osanov ◽  
James K. Guest
Keyword(s):  
Topology Optimization ◽  
Additive Manufacturing ◽  
Manufacturing Process ◽  
Three Dimensional ◽  
Design Tool ◽  
Geometric Constraints ◽  
Layer By Layer ◽  
Simple Modification ◽  
Complex Structural ◽  
Manufacturing Technologies

The rapid advance of additive manufacturing technologies has provided new opportunities for creating complex structural shapes. In order to fully exploit these opportunities, however, engineers must re-think the design process and leverage these new capabilities while respecting manufacturing constraints inherent in various processes. Topology optimization, as a free-from design tool, is a potentially powerful approach to addressing this design challenge provided the manufacturing process is properly accounted for. This work examines geometric constraints related to feature size and the layer-by-layer nature of the manufacturing process. A simple modification to the Heaviside Projection Method, an approach for naturally achieving geometric constraints in topology optimization, is proposed and demonstrated to have clear, understandable impact on three-dimensional optimized beam designs.

Minimization of Cost and Print Time of Additive Manufacturing via Topology Optimization

2018 ◽  
Author(s):  
Graeme Sabiston ◽  
Luke Ryan ◽  
Il Yong Kim
Keyword(s):  
Topology Optimization ◽  
Additive Manufacturing ◽  
Surface Area ◽  
Large Scale ◽  
Time Factors ◽  
Design Tool ◽  
Support Material ◽  
Manufacturing Operations ◽  
Volume Yield ◽  
The Cost

As the field of design for additive manufacturing continues to evolve and accelerate towards admitting more robust designs requiring fewer instances of user-intervention, we will see the conventional design cycle evolve dramatically. However, to fully take advantage of this emerging technology — particularly with respect to large scale manufacturing operations — considerations of productivity from a fiscal perspective are sure to become of the utmost importance. A mathematical model incorporating the cost and time factors associated with additive manufacturing processes has been developed and implemented as a multi-weighted single-objective topology optimization algorithm. The aforementioned factors have been identified as component surface area and volume of support material. These quantities are optimized alongside compliance, producing a design tool that gives the user the option to choose the relative weighting of performance over cost. In two academic examples, minimization of compliance alongside surface area and support structure volume yield geometries demonstrating that considerable decreases in support material in particular can be achieved without sacrificing significant part compliance.

The Use of Additive Manufacturing Techniques in the Construction of Model-Scale Propellers

2013 ◽  
Author(s):  
Matthew Garvin ◽  
Mohammed Islam ◽  
David Molyneux ◽  
Paul Herrington
Keyword(s):  
Additive Manufacturing ◽  
Computer Aided Design ◽  
Open Water ◽  
Cost Effective ◽  
Design Tool ◽  
Efficient Manner ◽  
Model Scale ◽  
Order Of Magnitude ◽  
Manufacturing Techniques ◽  
Open Water Performance

Historically, it has been expensive for model test basins to supply custom model-scale propellers for ship propulsion experiments, due to the high cost of traditional propeller fabrication methods. This paper presents a new method of manufacturing model propellers in a cost effective and time efficient manner. A new computer aided design tool has been developed to quickly develop propeller geometry, which can then be built using additive manufacturing processes. These processes reduce the cost of manufacturing propellers by an order of magnitude compared to machined metal propellers. The results of a study comparing propeller open water and self-propulsion experiments using traditional metal propellers to newly developed plastic propellers are presented. This study also includes an evaluation of the effect of surface roughness on the open water performance coefficients. The measured propulsive performance coefficients of the plastic propellers were within 2% of that of geometrically similar metal propellers with the same blade roughness.

Understanding the Role of Additive Manufacturing Knowledge in Stimulating Design Innovation for Novice Designers

2018 ◽  
Author(s):  
Sheng Yang ◽  
Thomas Page ◽  
Yaoyao Fiona Zhao
Keyword(s):  
Experimental Study ◽  
Additive Manufacturing ◽  
Experimental Studies ◽  
Radical Innovation ◽  
Positive Influence ◽  
Future Research ◽  
Disruptive Technology ◽  
Architectural Innovation ◽  
Novice Designers ◽  
Design Innovation

Additive manufacturing (AM) is recognized as a disruptive technology that offers significant potentials for innovative design. Prior experimental studies have revealed that novice designers provided with AM knowledge (AMK) resources can generate a higher quantity and quality of solutions in contrast with the control groups. However, these studies have adopted general evaluation metrics that fall short in correlating AMK with radical or architectural innovation. This deficiency directly affects how AMK should be captured, modeled, and delivered so that novel opportunities may be more efficiently utilized in the ideation stage. To refine the understanding of AMK’s role in stimulating design innovation, an experimental study is conducted with two design projects: (a) a mixer design project, and (b) a hairdryer redesign project. The former of which aims to discover whether AMK inspiration increases the quantity and novelty of working principles (i.e. radical innovation), while the latter examines the influence of AMK on layout and feature novelty (i.e. architectural innovation). The experimental study indicates that AMK does have a positive influence on architectural innovation, but the effects on radical innovation are very limited if the provided AMK is functionally irrelevant to the design problems. Two strategies are proposed to aid the ideation process in maximizing the possibility of identifying AM potentials which facilitate radical innovation. The limitations of this study and future research plans are also discussed.

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