Redesigning a Reaction Control Thruster for Metal-Based Additive Manufacturing: A Case Study in Design for Additive Manufacturing

2016 ◽  
Author(s):  
Matthew R. Woods ◽  
Nicholas A. Meisel ◽  
Timothy W. Simpson ◽  
Corey J. Dickman
Keyword(s):  
Additive Manufacturing ◽  
Attitude Control ◽  
Development Effort ◽  
Design For Additive Manufacturing ◽  
Powder Bed ◽  
Subtractive Manufacturing ◽  
End Use ◽  
Manufacturing Time ◽  
Novel Design

Prior research has shown that powder bed fusion additive manufacturing (AM) can be used to make functional, end-use components from powdered metallic alloys, such as Inconel® 718 super alloy. However, these end-use products are often based on designs developed for more traditional subtractive manufacturing processes without taking advantage of the unique design freedoms afforded by AM. In this paper, we present a case study involving the redesign of NASA’s existing “Pencil” thruster used for spacecraft attitude control. The initial “Pencil” thruster was designed for, and manufactured using, traditional subtractive methods. The main focus in this paper is to (a) review the Design for Additive Manufacturing (DfAM) concepts and considerations used in redesigning the thruster and (b) compare it with a parallel development effort redesigning the original thruster to be manufactured more effectively using subtractive processes. The results from this study show how developing end-use AM components using DfAM guidelines can significantly reduce manufacturing time and costs while introducing new and novel design geometries.

Redesigning a Reaction Control Thruster for Metal-Based Additive Manufacturing: A Case Study in Design for Additive Manufacturing

2017 ◽  
Vol 139 (10) ◽  
Author(s):  
Nicholas A. Meisel ◽  
Matthew R. Woods ◽  
Timothy W. Simpson ◽  
Corey J. Dickman
Keyword(s):  
Additive Manufacturing ◽  
Attitude Control ◽  
Manufacturing Processes ◽  
Development Effort ◽  
Design For Additive Manufacturing ◽  
Powder Bed ◽  
Subtractive Manufacturing ◽  
End Use ◽  
Manufacturing Time

Prior research has shown that powder-bed fusion (PBF) additive manufacturing (AM) can be used to make functional, end-use components from powdered metallic alloys, such as Inconel® 718 superalloy. However, these end-use components and products are often based on designs developed for more traditional subtractive manufacturing processes and do not take advantage of the unique design freedoms afforded by AM. In this paper, we present a case study involving the redesign of NASA’s existing “pencil” thruster used for spacecraft attitude control. The initial pencil thruster was designed for and manufactured using traditional subtractive methods. The main focus in this paper is to (a) identify the need for and use of both opportunistic and restrictive design for additive manufacturing (DfAM) concepts and considerations in redesigning the thruster for fabrication with PBF AM and (b) compare the resulting DfAM thruster with a parallel development effort redesigning the original thruster to be manufactured more effectively using subtractive manufacturing processes. The results from this case study show how developing end-use AM components using specific DfAM guidelines can significantly reduce manufacturing time and costs while enabling new and novel design geometries.

A Design for Additive Manufacturing Ontology

2016 ◽  
Author(s):  
Mahmoud Dinar ◽  
David W. Rosen
Keyword(s):  
Additive Manufacturing ◽  
Knowledge Base ◽  
System Integration ◽  
Domain Knowledge ◽  
Description Logic ◽  
Design For Additive Manufacturing ◽  
Traditional Design ◽  
Subtractive Manufacturing ◽  
Future Work

Design for additive manufacturing (DFAM) gives designers new freedoms to create complex geometries and combine parts into one. However, it has its own limitations, and more importantly, requires a shift in thinking from traditional design for subtractive manufacturing. There is a lack of formal and structured guidelines, especially for novice designers. To formalize knowledge of DFAM, we have developed an ontology using formal OWL/RDF representations in the Protégé tool. The description logic formalism facilitates expressing domain knowledge as well as capturing information from benchmark studies. This is demonstrated in a case study with three design features: revolute joint, thread assembly (screw connection), and slider-crank. How multiple instances (build events) are stored and retrieved in the knowledge base is discussed in light of modeling requirements for the DFAM knowledge base: knowledge capture and reuse, supporting a tutoring system, integration into CAD tools. A set of competency questions are described to evaluate knowledge retrieval. Examples are given with SPARQL queries. Knowledge documentation is the main objective of the current ontology. However, description logic creates multiple opportunities for future work, including representing and reasoning about DFAM rules in a structured modular hierarchy, discovering new rules with induction, and recognizing patterns with classification, e.g., what leads to “successful” vs. “unsuccessful” fabrications.

scholarly journals GEOMETRICAL BENCHMARKING OF LASER POWDER BED FUSION SYSTEMS BASED ON DESIGNER NEEDS

2021 ◽  
Vol 1 ◽  
pp. 1657-1666
Author(s):  
Joaquin Montero ◽  
Sebastian Weber ◽  
Christoph Petroll ◽  
Stefan Brenner ◽  
Matthias Bleckmann ◽  
...  
Keyword(s):  
Additive Manufacturing ◽  
Use Case ◽  
Powder Bed Fusion ◽  
Design For Additive Manufacturing ◽  
Laser Powder Bed Fusion ◽  
Measuring Systems ◽  
Powder Bed ◽  
Geometric Dimensioning And Tolerancing ◽  
Uncertainty Map ◽  
New System

AbstractCommercially available metal Laser Powder Bed Fusion (L-PBF) systems are steadily evolving. Thus, design limitations narrow and the diversity of achievable geometries widens. This progress leads researchers to create innovative benchmarks to understand the new system capabilities. Thereby, designers can update their knowledge base in design for additive manufacturing (DfAM). To date, there are plenty of geometrical benchmarks that seek to develop generic test artefacts. Still, they are often complex to measure, and the information they deliver may not be relevant to some designers. This article proposes a geometrical benchmarking approach for metal L-PBF systems based on the designer needs. Furthermore, Geometric Dimensioning and Tolerancing (GD&T) characteristics enhance the approach. A practical use-case is presented, consisting of developing, manufacturing, and measuring a meaningful and straightforward geometric test artefact. Moreover, optical measuring systems are used to create a tailored uncertainty map for benchmarking two different L-PBF systems.

scholarly journals An Optimization Workflow in Design for Additive Manufacturing

2021 ◽  
Vol 11 (6) ◽  
pp. 2572
Author(s):  
Stefano Rosso ◽  
Federico Uriati ◽  
Luca Grigolato ◽  
Roberto Meneghello ◽  
Gianmaria Concheri ◽  
...  
Keyword(s):  
Additive Manufacturing ◽  
Structural Optimization ◽  
Geometric Model ◽  
Complex Geometries ◽  
Design Phase ◽  
Design For Additive Manufacturing ◽  
Engineering Software ◽  
Embodiment Design ◽  
Pros And Cons

Additive Manufacturing (AM) brought a revolution in parts design and production. It enables the possibility to obtain objects with complex geometries and to exploit structural optimization algorithms. Nevertheless, AM is far from being a mature technology and advances are still needed from different perspectives. Among these, the literature highlights the need of improving the frameworks that describe the design process and taking full advantage of the possibilities offered by AM. This work aims to propose a workflow for AM guiding the designer during the embodiment design phase, from the engineering requirements to the production of the final part. The main aspects are the optimization of the dimensions and the topology of the parts, to take into consideration functional and manufacturing requirements, and to validate the geometric model by computer-aided engineering software. Moreover, a case study dealing with the redesign of a piston rod is presented, in which the proposed workflow is adopted. Results show the effectiveness of the workflow when applied to cases in which structural optimization could bring an advantage in the design of a part and the pros and cons of the choices made during the design phases were highlighted.

Development of a Design for Additive Manufacturing Worksheet for Medical Casts

2021 ◽  
Author(s):  
Heena Noh ◽  
Kijung Park ◽  
Kiwon Park ◽  
Gül E. Okudan Kremer
Keyword(s):  
Additive Manufacturing ◽  
High Strength ◽  
Design Guidelines ◽  
Operational Performance ◽  
Design For Additive Manufacturing ◽  
Trade Offs ◽  
Novice Designers ◽  
Criteria Importance ◽  
Design For Am

Abstract Traditional plaster casts often cause dermatitis due to disadvantages in usability and wearability. Additive manufacturing (AM) can fabricate customized casts to have light-weight, high strength, and better air permeability. Although existing studies have provided design for additive manufacturing (DfAM) guidelines to facilitate design applications for AM, most relevant studies focused on the mechanical properties of outputs and too general/specific design guidelines; novice designers may still have difficulty understanding trade-offs between functional and operational performance of various DfAM aspects for medical casts. As a response, this study proposes a DfAM worksheet for medical casts to effectively guide novice designers. First, important DfAM criteria and their possible solutions for medical casts are examined through a literature review to construct a basic DfAM framework for medical casts. Next, a scoring system that considers relative criteria importance and criteria evaluation from both functional and operational perspectives is developed to identify the overall suitability of a medical cast design for AM. A case study of finger cast designs was performed to identify the DfAM performance of the sample designs along with redesign requirements suggested by the worksheet. The proposed worksheet would be used to achieve rapid medical cast design by objectively assessing its suitability for AM.

Design for Additive Manufacturing in the Cloud Platform

2017 ◽  
Author(s):  
Yuanbin Wang ◽  
Robert Blache ◽  
Xun Xu
Keyword(s):  
Knowledge Management ◽  
Decision Support ◽  
Additive Manufacturing ◽  
Full Advantage ◽  
New Technologies ◽  
Design Stage ◽  
Design For Additive Manufacturing ◽  
Cloud Platform ◽  
Am Processes

Additive manufacturing (AM) has experienced a phenomenal expansion in recent years and new technologies and materials rapidly emerge in the market. Design for Additive Manufacturing (DfAM) becomes more and more important to take full advantage of the capabilities provided by AM. However, most people still have limited knowledge to make informed decisions in the design stage. Therefore, an interactive DfAM system in the cloud platform is proposed to enable people sharing the knowledge in this field and guide the designers to utilize AM efficiently. There are two major modules in the system, decision support module and knowledge management module. A case study is presented to illustrate how this system can help the designers understand the capabilities of AM processes and make rational decisions.

scholarly journals Design for Additive Manufacturing and for Machining in the Automotive Field

2021 ◽  
Vol 11 (16) ◽  
pp. 7559
Author(s):  
Elena Bassoli ◽  
Silvio Defanti ◽  
Emanuele Tognoli ◽  
Nicolò Vincenzi ◽  
Lorenzo Degli Esposti
Keyword(s):  
Additive Manufacturing ◽  
Process Simulation ◽  
Automotive Application ◽  
Powder Bed Fusion ◽  
Design For Additive Manufacturing ◽  
Good Correspondence ◽  
Powder Bed ◽  
Aluminum Component ◽  
Machining Operations ◽  
First Time

High cost, unpredictable defects and out-of-tolerance rejections in final parts are preventing the complete deployment of Laser-based Powder Bed Fusion (LPBF) on an industrial scale. Repeatability, speed and right-first-time manufacturing require synergistic design approaches. In addition, post-build finishing operations of LPBF parts are the object of increasing attention to avoid the risk of bottlenecks in the machining step. An aluminum component for automotive application was redesigned through topology optimization and Design for Additive Manufacturing. Simulation of the build process allowed to choose the orientation and the support location for potential lowest deformation and residual stresses. Design for Finishing was adopted in order to facilitate the machining operations after additive construction. The optical dimensional check proved a good correspondence with the tolerances predicted by process simulation and confirmed part acceptability. A cost and time comparison versus CNC alone attested to the convenience of LPBF unless single parts had to be produced.

scholarly journals Evaluation of Assembly Part Build Orientation in Additive Manufacturing Environment using Data Envelopment Analysis

2019 ◽  
Vol 293 ◽  
pp. 02002 ◽  
Author(s):  
Kasin Ransikarbum ◽  
Rapeepan Pitakaso ◽  
Namhun Kim
Keyword(s):  
Data Envelopment Analysis ◽  
Additive Manufacturing ◽  
Process Planning ◽  
Data Envelopment ◽  
3D Objects ◽  
Lathe Machine ◽  
Subtractive Manufacturing ◽  
Personal Use ◽  
Using Data

Whereas Subtractive Manufacturing (SM) is a process by which 3D objects are constructed by cutting material away from a solid block of material, such as milling and lathe machine; Additive Manufacturing (AM) is a synonym for 3D printing and other processes by which 3D objects are constructed by successively depositing material in layers. Recently, AM has become widespread for both industrial and personal use thanks to the freedom and benefits it provides in designing parts, reducing lead time, improving inventory, and supply chain. However, few studies examine process planning issues in AM. In addition, existing studies focus on production of an individual part alone. In this study, we examine the assembly orientation alternatives’ efficiency using Data Envelopment Analysis (DEA) technique for different AM technologies and their associated materials under conflicting criteria. A case study of hardware fasteners using bolt and nut fabrication is illustrated in the study. Our results show that different AM technologies and materials clearly impact efficiency of part production and thus suggest optimal orientation in AM process planning platform.

Quantifying Powder Losses and Analyzing Powder Conditions in order to Determine Material Efficiency in Laser Beam Melting

2016 ◽  
Vol 856 ◽  
pp. 231-237 ◽  
Author(s):  
Max Lutter-Günther ◽  
Alexander Hofmann ◽  
Christoph Hauck ◽  
Christian Seidel ◽  
Gunther Reinhart
Keyword(s):  
Laser Beam ◽  
Experimental Studies ◽  
Manufacturing Processes ◽  
Ecological Evaluation ◽  
Powder Bed ◽  
Material Efficiency ◽  
Laser Beam Melting ◽  
Measurement Results ◽  
Subtractive Manufacturing ◽  
End Use

Laser Beam Melting (LBM) is an additive manufacturing process, which is increasingly applied for the production of end use parts. One advantage of this powder bed fusion technology lies in the high material efficiency in comparison with subtractive manufacturing processes (i. e. milling, lathing). However, only few experimental studies have been conducted on the material efficiency of LBM. For the accurate evaluation of the LBM material efficiency, empirical values for powder losses are required. Furthermore, a lack of terminology for waste types and powder conditions in the context of LBM impedes communication and research on the topic. The presented paper aims to increase the understanding of material efficiency and powder conditions in Laser Beam Melting. A quantitative analysis of waste types is presented for different LBM application scenarios. This sets a basis for the ecological evaluation and comparison with conventional manufacturing processes. In order to achieve the aim, a terminology is introduced for waste types and powder conditions in the context of powder bed-based additive processes. Therefore, considerations regarding powder quality are taken into account. For the quantification of powder losses, the experimental setup and measurement results are described. Furthermore, loss types and their significance are analyzed and discussed.

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