Shape and Performance Controlled Advanced Design for Additive Manufacturing: A Review of Slicing and Path Planning

2019 ◽  
Vol 142 (1) ◽  
Author(s):  
Donghua Zhao ◽  
Weizhong Guo
Keyword(s):  
Additive Manufacturing ◽  
Path Planning ◽  
Rapid Development ◽  
Optimization Methods ◽  
Current Status ◽  
Curved Surfaces ◽  
Support Structures ◽  
Design For Additive Manufacturing ◽  
And Performance ◽  
And Function

AbstractAdditive manufacturing (AM) brings out a revolution of how the products are designed and manufactured. To obtain desired components, advanced design for additive manufacturing (ADfAM) is widely emphasized in geometry, material, and function design. 3D slicing and path planning, which are the critical steps of ADfAM, directly determine manufacturing process variables, shape, and performance of printed parts. For widely used planar slicing, the contradiction between accuracy and build time has attracted considerable attention and efforts, leading to various novel and optimization methods. Nevertheless, curved surfaces and slopes along the build direction constrain the surfaces to be smooth due to the inherent staircase effect of AM. Meanwhile, there is significant anisotropy of the printed piece making it sensitive to any shear (or bending) stress. Moreover, support structures for the overhang part are necessary when building along one direction, resulting in time-consuming and cost-expensive process. Due to the rapid development of 3D slicing and path planning, and various newly proposed methods, there is a lack of comprehensive knowledge. Notwithstanding, there are fewer literature reviews concerning planar slicing and filling strategy. Less attention has been paid to non-planar slicing, path planning on curved surfaces, and multi-degree of freedom (DOF) AM equipment, as well as printing under pressure. Hence, it is significant to get a comprehensive understanding of current status and challenges. Then, with suitable technologies, the printed parts with improved surface quality, minimum support structures, and better isotropy could be acquired. Finally, the recommendation for the future development of slicing and path planning is also provided.

scholarly journals Path Planning Strategies to Optimize Accuracy, Quality, Build Time and Material Use in Additive Manufacturing: A Review

Micromachines ◽  
2020 ◽  
Vol 11 (7) ◽  
pp. 633 ◽  
Author(s):  
Jingchao Jiang ◽  
Yongsheng Ma
Keyword(s):  
Additive Manufacturing ◽  
Path Planning ◽  
Rapid Development ◽  
3D Models ◽  
Current Status ◽  
Layer By Layer ◽  
The Future ◽  
Build Time ◽  
Subtractive Manufacturing ◽  
Planning Strategies

Additive manufacturing (AM) is the process of joining materials layer by layer to fabricate products based on 3D models. Due to the layer-by-layer nature of AM, parts with complex geometries, integrated assemblies, customized geometry or multifunctional designs can now be manufactured more easily than traditional subtractive manufacturing. Path planning in AM is an important step in the process of manufacturing products. The final fabricated qualities, properties, etc., will be different when using different path strategies, even using the same AM machine and process parameters. Currently, increasing research studies have been published on path planning strategies with different aims. Due to the rapid development of path planning in AM and various newly proposed strategies, there is a lack of comprehensive reviews on this topic. Therefore, this paper gives a comprehensive understanding of the current status and challenges of AM path planning. This paper reviews and discusses path planning strategies in three categories: improving printed qualities, saving materials/time and achieving objective printed properties. The main findings of this review include: new path planning strategies can be developed by combining some of the strategies in literature with better performance; a path planning platform can be developed to help select the most suitable path planning strategy with required properties; research on path planning considering energy consumption can be carried out in the future; a benchmark model for testing the performance of path planning strategies can be designed; the trade-off among different fabricated properties can be considered as a factor in future path planning design processes; and lastly, machine learning can be a powerful tool to further improve path planning strategies in the future.

scholarly journals REVIEW OF DESIGN HEURISTICS AND DESIGN PRINCIPLES IN DESIGN FOR ADDITIVE MANUFACTURING

2021 ◽  
Vol 1 ◽  
pp. 2571-2580
Author(s):  
Filip Valjak ◽  
Angelica Lindwall
Keyword(s):  
Additive Manufacturing ◽  
Design Process ◽  
Research Question ◽  
Design Principles ◽  
Current Status ◽  
Design For Additive Manufacturing ◽  
Design Heuristics ◽  
Similarities And Differences ◽  
Definition Of ◽  
Support Methods

AbstractThe advent of additive manufacturing (AM) in recent years have had a significant impact on the design process. Because of new manufacturing technology, a new area of research emerged – Design for Additive Manufacturing (DfAM) with newly developed design support methods and tools. This paper looks into the current status of the field regarding the conceptual design of AM products, with the focus on how literature sources treat design heuristics and design principles in the context of DfAM. To answer the research question, a systematic literature review was conducted. The results are analysed, compared and discussed on three main points: the definition of the design heuristics and the design principles, level of support they provide, as well as where and how they are used inside the design process. The paper highlights the similarities and differences between design heuristics and design principles in the context of DfAM.

An Investigation Into the Driving Factors of Creativity in Design for Additive Manufacturing

2017 ◽  
Author(s):  
Michael Barclift ◽  
Timothy W. Simpson ◽  
Maria Alessandra Nusiner ◽  
Scarlett Miller
Keyword(s):  
Additive Manufacturing ◽  
Self Report ◽  
Risk Attitudes ◽  
Design For Additive Manufacturing ◽  
Domain Specific ◽  
Common Framework ◽  
And Performance ◽  
Student Risk ◽  
Prior Experiences ◽  
Design Freedom

Additive manufacturing (AM) provides engineers with nearly unlimited design freedom, but how much do they take advantage of that freedom? The objective is to understand what factors influence a designer’s creativity and performance in Design for Additive Manufacturing (DFAM). Inspired by the popular Marshmallow Challenge, this exploratory study proposes a framework in which participants apply their DFAM skills in sketching, CAD modeling, 3D-Printing, and a part testing task. Risk attitudes are assessed through the Engineering Domain-Specific Risk-Taking (E-DOSPERT) scale, and prior experiences are captured by a self-report skills survey. Multiple regression analysis found that the average novelty of the participant’s ideas, engineering degree program, and risk seeking preference were statistically significant when predicting the performance of their ideas in AM. This study provides a common framework for AM educators to assess students’ understanding and creativity in DFAM, while also identifying student risk attitudes when conducting an engineering design task.

Material-structure-performance integrated laser-metal additive manufacturing

Science ◽  
2021 ◽  
Vol 372 (6545) ◽  
pp. eabg1487
Author(s):  
Dongdong Gu ◽  
Xinyu Shi ◽  
Reinhart Poprawe ◽  
David L. Bourell ◽  
Rossitza Setchi ◽  
...  
Keyword(s):  
Additive Manufacturing ◽  
High Performance ◽  
Material Structure ◽  
Metal Additive Manufacturing ◽  
Material Development ◽  
Design And Manufacturing ◽  
And Performance ◽  
The Right ◽  
And Function ◽  
Metal Additive

Laser-metal additive manufacturing capabilities have advanced from single-material printing to multimaterial/multifunctional design and manufacturing. Material-structure-performance integrated additive manufacturing (MSPI-AM) represents a path toward the integral manufacturing of end-use components with innovative structures and multimaterial layouts to meet the increasing demand from industries such as aviation, aerospace, automobile manufacturing, and energy production. We highlight two methodological ideas for MSPI-AM—“the right materials printed in the right positions” and “unique structures printed for unique functions”—to realize major improvements in performance and function. We establish how cross-scale mechanisms to coordinate nano/microscale material development, mesoscale process monitoring, and macroscale structure and performance control can be used proactively to achieve high performance with multifunctionality. MSPI-AM exemplifies the revolution of design and manufacturing strategies for AM and its technological enhancement and sustainable development.

scholarly journals Design and Performance Assessment of Innovative Eco-Efficient Support Structures for Additive Manufacturing by Photopolymerization

2017 ◽  
Vol 21 (S1) ◽  
pp. S179-S190 ◽  
Author(s):  
Andrés Díaz Lantada ◽  
Adrián de Blas Romero ◽  
Álvaro Sánchez Isasi ◽  
Diego Garrido Bellido
Keyword(s):  
Additive Manufacturing ◽  
Performance Assessment ◽  
Support Structures ◽  
And Performance

Generating support structures for additive manufacturing with continuum topology optimization methods

2019 ◽  
Vol 25 (2) ◽  
pp. 232-246 ◽  
Author(s):  
Yang Liu ◽  
Zuyu Li ◽  
Peng Wei ◽  
Shikui Chen
Keyword(s):  
Topology Optimization ◽  
Additive Manufacturing ◽  
Rapid Development ◽  
Load Condition ◽  
Practical Significance ◽  
Heaviside Function ◽  
Optimal Topology ◽  
Support Structures ◽  
Content Type ◽  
Material Volume

PurposeThe purpose of this paper is to explore the possibility of combining additive manufacturing (AM) with topology optimization to generate support structures for addressing the challenging overhang problem. The overhang problem is considered as a constraint, and a novel algorithm based on continuum topology optimization is proposed.Design/methodology/approachA mathematical model is formulated, and the overhang constraint is embedded implicitly through a Heaviside function projection. The algorithm is based on the Solid Isotropic Material Penalization (SIMP) method, and the optimization problem is solved through sensitivity analysis.FindingsThe overhang problem of the support structures is fixed. The optimal topology of the support structures is developed from a mechanical perspective and remains stable as the material volume of support structures changes, which allows engineers to adjust the material volume to save cost and printing time and meanwhile ensure sufficient stiffness of the support structures. Three types of load conditions for practical application are considered. By discussing the uniform distributive load condition, a compromise result is achieved. By discussing the point load condition, the removal work of support structures after printing is alleviated. By discussing the most unfavorable load condition, the worst collapse situation of the printing model during printing process is sufficiently considered. Numerical examples show feasibility and effectiveness of the algorithm.Research limitations/implicationsThe proposed algorithm involves time-consuming finite element analysis and iterative solution, which increase the computation burden. Only the overhang constraint and the minimum compliance problem are discussed, while other constraints and objective functions may be of interest.Practical implicationsCompared with most of the existing heuristic or geometry-based support-generating algorithms, the proposed algorithm develops support structures for AM from a mechanical perspective, which is necessary for support structures particularly used in AM for mega-scale construction such as architectures and sculptures to ensure printing success and accuracy of the printed model.Social implicationsWith the rapid development of AM, complicated structures result from topology optimization are available for fabrication. The present paper demonstrates a combination of AM and topology optimization, which is the trend of fabricating manner in the future.Originality/valueThis paper remarks the first of attempts to use continuum topology optimization method to generate support structures for AM. The methodology used in this work is theoretically meaningful and conclusions drawn in this paper can be of important instruction value and practical significance.

Nanomaterials in Liver Regeneration: The Prospect for Application

Nano LIFE ◽  
2018 ◽  
Vol 08 (04) ◽  
pp. 1841005
Author(s):  
Xiuhua Li ◽  
Yang Yang ◽  
Wei Liu ◽  
Wenjian Chen ◽  
Kangyuan Hu ◽  
...  
Keyword(s):  
Liver Regeneration ◽  
Cell Function ◽  
Rapid Development ◽  
Hepatocyte Transplantation ◽  
Current Status ◽  
Immune Rejection ◽  
Complete Understanding ◽  
And Function ◽  
Hepatocyte Growth

Hepatocyte transplantation has been proved an effective method to help liver regeneration by replacing host deficient cells caused by various disorders or injuries. However, several problems existing in hepatocyte transplantation have limited the clinical application of the technology. These problems include limited survival time of transplanted cells, immune rejection in xenotransplantation and insufficient transplantation efficiency. The rapid development of nanotechnology provides an opportunity for solving these problems. Application of nanomaterials in liver regeneration has been frequently reported recently. According to these researches, nanomaterials have advantages on the aspects of helping cell adhesion and growth, maintaining cell function and inducing cell differentiation. What is more, nanomaterials also exhibited its advantage on cell migration tracking, thus could help to monitor the cells transplantation and noninvasive diagnosis. For the further application of nanomaterials in liver regeneration, a complete understanding of current progress will be necessary and helpful. Our goal in this review is to summarize the current status of the applications of nanomaterials in hepatocyte transplantation. We will focus on nanomaterials that acted as scaffolds for hepatocyte growth and function maintenance, delivery cargo for improving hepatocyte transplantation and trackers for in vivo monitoring.

scholarly journals Advanced Design for Additive Manufacturing: 3D Slicing and 2D Path Planning

10.5772/63042 ◽  
2016 ◽  
Author(s):  
Donghong Ding ◽  
Zengxi Pan ◽  
Dominic Cuiuri ◽  
Huijun Li ◽  
Stephen van Duin
Keyword(s):  
Additive Manufacturing ◽  
Path Planning ◽  
Design For Additive Manufacturing

Application of Topology Optimization and Design for Additive Manufacturing Guidelines on an Automotive Component

2016 ◽  
Author(s):  
Sai Nithin Reddy K. ◽  
Vincent Maranan ◽  
Timothy W. Simpson ◽  
Todd Palmer ◽  
Corey J. Dickman
Keyword(s):  
Topology Optimization ◽  
Additive Manufacturing ◽  
Low Cost ◽  
Engineering Practice ◽  
Optimized Design ◽  
Design For Additive Manufacturing ◽  
Manufacturing Costs ◽  
Cost Structures ◽  
And Performance

Topology optimization is a well-established engineering practice to optimize the design and layout of parts to create lightweight and low-cost structures, which have historically been difficult, or impossible, to make. Additive Manufacturing (AM) provides the freedom to fabricate the complex and organic shapes that topology optimization often generates. In this paper we use topology optimization to create lightweight designs while conforming to additive manufacturing constraints related to overhanging features and unsupported surfaces when using metallic materials. More specifically, we use design for additive manufacturing (DfAM) rules along with topology optimization to study the tradeoffs between the weight of the part, support requirements, manufacturing costs, and performance. The case study entails redesigning an upright on the SAE Formula student racecar to reduce support structures and manufacturing and material cost when using Direct Metal Laser Sintering (DMLS). Manufacturing the optimized design without applying DfAM rules required support material up to 202.4% of the volume of the model. Using DfAM, the upright is redesigned and manufactured with supports requiring less than 15% of the volume of the model. The results demonstrate the challenges in achieving a balance between weight reduction, manufacturing costs, and factor of safety of the design.

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