Impact of Timing in the Design Process on Students' Application of Design for Additive Manufacturing Heuristics

2021 ◽  
pp. 1-56
Author(s):  
Anastasia Schauer ◽  
Kenton Fillingim ◽  
Katherine Fu
Keyword(s):  
Additive Manufacturing ◽  
Design Process ◽  
Design Activity ◽  
Second Phase ◽  
Design For Additive Manufacturing ◽  
Additional Information ◽  
Design Heuristics ◽  
Traditional Manufacturing ◽  
The Way

Abstract The goal of this work is to study the way student designers use design for additive manufacturing (DfAM) rules, or heuristics. It can be challenging for novice designers to succeed at creating successful designs for additive manufacturing (AM), given its differences from traditional manufacturing methods. A study was carried out to investigate the way novices apply DfAM heuristics when they receive them at different points in the design process. A design problem was presented to students, and three different groups of student participants were given a lecture on DfAM heuristics at three different points in the design process. The novelty and quality of each of the resulting designs was evaluated. Results indicate that although the DfAM heuristics lecture had no impact on the overall quality of the designs generated, participants who were given the heuristics lecture after the initial design session produced designs that were better suited for 3D printing in the second phase of the design activity. However, receiving this additional information appears to prevent students from creatively iterating upon their initial designs, as participants in this group did not experience an increase in novelty between the two sessions. Additionally, receiving the heuristics lecture increased all students' perceptions of their ability to perform DfAM-related tasks. These results validate the practicality of design heuristics as AM training tools while also emphasizing the importance of iteration in the design process.

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.

Teaching Design Freedom: Exploring the Effects of Design for Additive Manufacturing Education on the Cognitive Components of Students’ Creativity

2018 ◽  
Author(s):  
Rohan Prabhu ◽  
Scarlett R. Miller ◽  
Timothy W. Simpson ◽  
Nicholas A. Meisel
Keyword(s):  
Additive Manufacturing ◽  
Design Process ◽  
Self Efficacy ◽  
Domain Knowledge ◽  
Engineering Students ◽  
Design For Additive Manufacturing ◽  
Task Motivation ◽  
Cognitive Components ◽  
Traditional Manufacturing ◽  
Education Groups

Design for manufacturing provides engineers with a structure for accommodating the limitations of traditional manufacturing processes. However, little emphasis is typically given to the capabilities of processes that enable novel design geometries, which are often a point of focus when designing products to be made with additive manufacturing (AM) technologies. In addition, limited research has been conducted to understand how knowledge of both the capabilities (i.e., opportunistic) and limitations (i.e., restrictive aspects) of AM affects design outcomes. This study aims to address this gap by investigating the effect of no, restrictive, and both, opportunistic and restrictive (dual) design for additive manufacturing (DfAM) education on engineering students’ creative process. Based on the componential model of creativity [1], these effects were measured through changes in (1) motivation and interest in AM, (2) DfAM self-efficacy, and (3) the emphasis given to DfAM in the design process. These metrics were chosen as they represent the cognitive components of ‘task-motivation’ and ‘domain relevant skills’, which in turn influence the learning and usage of domain knowledge in creative production. The results of the study show that while the short (45 minute) DfAM intervention did not significantly change student motivation and interest towards AM, students showed high levels of motivation and interest towards AM, before the intervention. Teaching students different aspects of DfAM also resulted in an increase in their self-efficacy in the respective topics. However, despite showing a greater increase in self-efficacy in their respective areas of training, the students did not show differences in the emphasis they gave to these DfAM concepts, in the design process. Further, students from all three education groups showed higher use of restrictive concepts, in comparison to opportunistic DfAM.

Enhancing Creative Redesign through Multi-Modal Design Heuristics for Additive Manufacturing

2021 ◽  
pp. 1-52
Author(s):  
Alexandra Bloesch-Paidosh ◽  
Kristina Shea
Keyword(s):  
Additive Manufacturing ◽  
Design Process ◽  
User Studies ◽  
Novice User ◽  
Design Heuristics ◽  
Industrial Setting ◽  
Derived Design ◽  
Mind Set ◽  
Future Work ◽  
Early Phases

Abstract When designing for Additive Manufacturing (AM), designers often need assistance in breaking out of their conventional manufacturing mind-set. Previously, Blösch-Paidosh and Shea (2019) derived Design Heuristics for AM (DHAM) to assist designers in doing this during the early phases of the design process. This work proposes a set of 25 multi-modal cards and objects to accompany each of the Design Heuristics for AM and studies their effect through a series of controlled, novice user studies conducted using both teams and individuals who redesign a city E-Bike. The resulting AM concepts are analyzed in terms of the quantity of design modifications relevant for AM, AM-flexibility, novelty, and variety. It is found that the DHAM cards and objects increase the inclusion of AM concepts, AM modifications, and the unique capabilities of AM in the concepts generated by both individuals and teams. They also increase the creativity of the concepts generated by both individuals and teams, as measured through a series of defined metrics. Further, the objects in combination with the cards are more effective at stimulating the generation of a wider variety of designs than the cards alone. Future work will focus on studying the use of the DHAM cards and objects in an industrial setting.

scholarly journals Analysis of the Machining Process of Titanium Ti6Al-4V Parts Manufactured by Wire Arc Additive Manufacturing (WAAM)

Materials ◽  
2020 ◽  
Vol 13 (3) ◽  
pp. 766 ◽  
Author(s):  
Fernando Veiga ◽  
Alain Gil Del Val ◽  
Alfredo Suárez ◽  
Unai Alonso
Keyword(s):  
Additive Manufacturing ◽  
Arc Welding ◽  
Machine Tools ◽  
Optimal Strategies ◽  
Machining Process ◽  
Manufacturing Processes ◽  
Plasma Arc Welding ◽  
Traditional Manufacturing ◽  
Wire Arc Additive Manufacturing

In the current days, the new range of machine tools allows the production of titanium alloy parts for the aeronautical sector through additive technologies. The quality of the materials produced is being studied extensively by the research community. This new manufacturing paradigm also opens important challenges such as the definition and analysis of the optimal strategies for finishing-oriented machining in this type of part. Researchers in both materials and manufacturing processes are making numerous advances in this field. This article discusses the analysis of the production and subsequent machining in the quality of TI6Al4V produced by Wire Arc Additive Manufacturing (WAAM), more specifically Plasma Arc Welding (PAW). The promising results observed make it a viable alternative to traditional manufacturing methods.

Consideration of the Manufacturing Trajectories in a Global Design for Additive Manufacturing Methodology

2012 ◽  
Author(s):  
R. Ponche ◽  
O. Kerbrat ◽  
P. Mognol ◽  
J. Y. Hascoet
Keyword(s):  
Additive Manufacturing ◽  
Cost Reduction ◽  
Design Problem ◽  
Manufacturing Processes ◽  
Strong Impact ◽  
Direct Impact ◽  
Design For Additive Manufacturing ◽  
Physical Phenomena ◽  
Am Processes

Additive Manufacturing (AM) is a new way of part production which opens up new perspectives of conception as mass and cost reduction and increase of functionalities. However these processes have their own characteristics which as for all the manufacturing processes have a direct impact on the manufactured parts quality. Especially, because the manufacturing trajectories have a influence on the physical phenomena during the process, they have also a strong impact on the quality of the produced parts in terms of geometry. In this paper, the choice of manufacturing trajectories and their impacts on the final shape and quality of the parts is integrated into a global Design For Additive Manufacturing (DFAM) methodology which allows to move from functional specifications of a design problem to a proposition of an adapted part for AM processes.

scholarly journals Trans-Create – Co-Design with Persons with Severe Disabilities

2021 ◽  
Author(s):  
Birgitta Cappelen ◽  
Anders-Petter Andersson
Keyword(s):  
Assistive Technology ◽  
Design Process ◽  
Severe Disabilities ◽  
Design Methods ◽  
New Approach ◽  
Communication Situation ◽  
Good For ◽  
The Way

Technology has potential for improving the lives of persons with severe disabilities. But it’s a challenge to create technology that improves lives from a person’s own perspective. Co-design methods have therefore been used in the design of Assistive Technology, to include users in the design process. But it’s a challenge to ensure the quality of participation with persons with significantly different prerequisites for communication than ourselves. It’s hard to know if what we design is good for them in the way they themselves define it, in a communication situation, which has to be significantly different than traditional co-design. In this paper, we present a new approach to co-design with persons with severe disabilities. We call this process “trans-create”, based on the creative translation we use when translating between cultures. We found that by using familiar artifacts that could be added and removed in the co-design process, we had a language for communication. By adding a personalisable digital layer to the artifacts, we could adapt, scale and redesign both tangible, visual and sound qualities in the situation dynamically. For example, by making it possible for the user to choose and activate a pink music cover card (RFID) that turns the lighting of the entire room pink and changes the music. This implies changing the distinction between designer and user, between the design process and the use process, and the view of what we create during a co-design process. That is why we have chosen to call this process “trans-create”, instead of co-create, what we create for “living works”, instead of design, a hybridisation between design and use, process and result.

scholarly journals Evaluating the Potential of Design for Additive Manufacturing Heuristic Cards to Stimulate Novel Product Redesigns

2019 ◽  
Author(s):  
Alexandra Blösch-Paidosh ◽  
Saeema Ahmed-Kristensen ◽  
Kristina Shea
Keyword(s):  
Additive Manufacturing ◽  
Design For Additive Manufacturing ◽  
Effective Mechanism ◽  
Design Heuristics ◽  
Design Students ◽  
Functional Complexity ◽  
Team Design ◽  
Design Freedom ◽  
Design Heuristic ◽  
Tools And Methods

Abstract Additive manufacturing (AM) affords those who wield it correctly the benefits of shape, material, hierarchical, and functional complexity. However, many engineers and designers lack the training and experience necessary to take full advantage of these benefits. They require training, tools, and methods to assist them in gaining the enhanced design freedom made possible by additive manufacturing. This work, which is an extension of the authors’ previous work, explores if design heuristics for AM, presented in a card-based format, are an effective mechanism for helping designers achieve the design freedoms enabled by AM. The effectiveness of these design heuristic cards is demonstrated in an experiment with 27 product design students, by showing that there is an increase in the number of unique capabilities of AM being utilized, an increase in the AM novelty, and an increase in the AM flexibility of the generated concepts, when given access to the cards. Additionally, similar to the previous work, an increase in the number of interpreted heuristics and AM modifications present in the participants’ designs when they are provided with the heuristic cards is shown. Comparisons are also made between 8-heuristic and 29-heuristic experiments, but no conclusive statements regarding these comparisons can be drawn. Further user studies are planned to confirm the efficacy of this format at enhancing the design freedoms achieved in group and team design scenarios.

scholarly journals Experiments with visible and invisible materials: designing and building an ambiance

2019 ◽  
Vol 64 ◽  
pp. 02008
Author(s):  
Céline Drozd ◽  
Virginie Meunier ◽  
Antoine Mabire
Keyword(s):  
Design Process ◽  
Graduate School ◽  
Architectural Design ◽  
Sensory Quality ◽  
Building Materials ◽  
Sensory Experience ◽  
Physical Characteristics ◽  
Materials Used ◽  
The Way

This article relies on a workshop called “materials of ambiances” that is taking place at the Graduate School of Architecture of Nantes. It aims for the students to question the qualities of ambiances within spaces with an approach through the concept of material, making them aware of invisible materials (ambiances) from the manipulation of visible materials (building materials). The experimentation with materials holds a significant place: the students are asked to build an ambiance device to create a sensory experience in order to highlight every sensory quality of a material capable of producing an ambiance. The materials used for this experiment are mostly from fields beyond architecture as to think of potential misappropriations. It is about making sure that the student tests by himself the materials and recreates the connection between data from the experiment, and the physical characteristics given by the manufacturers and industrialists. The pedagogical experience that we present aims at creating within students an interest for the built material, to develop ambiance intentions to qualify projected spaces, which are not always measurable but always noticeable. This article proposes to turn back to the way the qualities of ambiances are felt, the misappropriations of materials are perceived, as well as the perspectives on the evolution of the architectural design process. This contribution is illustrated by an ambiance device whose the name is “Cosmic dream” built in 2018/2019 by Marilou Bach, Hugo Falaise, Carole Lyssandre and Charlotte Say.

scholarly journals An additive manufacturing oriented design approach to mechanical assemblies

2017 ◽  
Vol 5 (1) ◽  
pp. 3-18 ◽  
Author(s):  
Germain Sossou ◽  
Frédéric Demoly ◽  
Ghislain Montavon ◽  
Samuel Gomes
Keyword(s):  
Additive Manufacturing ◽  
Design Process ◽  
Design For Additive Manufacturing ◽  
Post Processing ◽  
Mechanical Assembly ◽  
Build Orientation ◽  
Assembly Design ◽  
Conventional Design ◽  
Downstream Processes ◽  
Assembly Operations

Abstract Firstly introduced as a prototyping process, additive manufacturing (AM) is being more and more considered as a fully-edged manufacturing process. The number of AM processes, along with the range of processed materials are expanding. AM has made manufacturable shapes that were too difficult (or even impossible) to manufacture with conventional technologies. This has promoted a shift in engineering design, from conventional design for manufacturing and assembly to design for additive manufacturing (DFAM). Research efforts into the DFAM field have been mostly dedicated to part's design, which is actually a requirement for a better industrial adoption. This has given rise to topologically optimized and/or latticed designs. However, since AM is also capable of manufacturing fully functional assemblies requiring a few or no assembly operations, there is a need for DFAM methodologies tackling product's development more holistically, and which are, therefore, dedicated to assembly design. Considering all the manufacturing issues related to AM of assembly-free mechanisms and available post-processing capabilities, this paper proposes a top-down assembly design methodology for AM in a proactive manner. Such an approach, can be seen as the beginning of a shift from conventional design for assembly (DFA) to a new paradigm. From a product's concept and a selected AM technology, the approach first provides assistance in the definition of the product architecture so that both functionality and successful manufacturing (including post-processing) are ensured. Particularly, build-orientation and downstream processes' characteristics are taken into account early in the design process. Secondly, for the functional flow (energy, material, signal) to be appropriately conveyed by the right amount of matter, the methodology provides guidance into how the components can be designed in a minimalism fashion leveraging the shape complexity afforded by AM. A mechanical assembly as case study is presented to illustrate the DFAM methodology. It is found that clearances and material (be it raw unprocessed material or support structures) within them plays a pivotal role in a successful assembly's design to be additively manufactured. In addition, the methodology for components' design proves to be an efficient alternative to topology optimization. Though, the approach can be extended by considering a strategy for part consolidation and the possibility to manufacture the assemblies with more than one AM process. As regards components' design, considering anisotropy can also improved the approach. Highlights Additive manufacturing is capable of printing fully functional assemblies without any assembly operations. It is found that Design For Additive Manufacturing is currently mainly focused on part's design. A process-independent, structured and systematic method for designing assembly-free mechanisms (for AM) is proposed. Build orientation and downstream processes (including post-processing capabilities) are taken into account early in the design process. A method - based on functional flows - for part's design in a minimalist fashion, is proposed.

Design Heuristics for Additive Manufacturing Validated Through a User Study1

2019 ◽  
Vol 141 (4) ◽  
Author(s):  
Alexandra Blösch-Paidosh ◽  
Kristina Shea
Keyword(s):  
Additive Manufacturing ◽  
Future Research ◽  
Original Design ◽  
Design Heuristics ◽  
The Media ◽  
Novice Designers ◽  
Traditional Manufacturing ◽  
High Level ◽  
Independent Design ◽  
The Impact

Additive manufacturing (AM) has unique capabilities when compared to traditional manufacturing, such as shape, hierarchical, functional, and material complexity, a fact that has fascinated those in research, industry, and the media for the last decade. Consequently, designers would like to know how they can incorporate AM's special capabilities into their designs but are often at a loss as how to do so. Design for additive manufacturing (DfAM) methods are currently in development, but the vast majority of existing methods are not tailored to the needs and knowledge of designers in the early stages of the design process. Therefore, we propose a set of process-independent design heuristics for AM aimed at transferring the high-level knowledge necessary for reasoning about functions, configurations, and parts to designers. Twenty-nine design heuristics for AM are derived from 275 AM artifacts. An experiment is designed to test their efficacy in the context of a redesign scenario with novice designers. The heuristics are found to positively influence the designs generated by the novice designers and are found to be more effective at communicating DfAM concepts in the early phases of redesign than a lecture on DfAM alone. Future research is planned to validate the impact with expert designers and in original design scenarios.

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