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 Analysis and characterization of additive manufacturing processes

2021 ◽  
Vol 13 (4) ◽  
pp. 167-180
Author(s):  
Andra TOFAN-NEGRU ◽  
Cristian BARBU ◽  
Amado STEFAN ◽  
Ioana-Carmen BOGLIS
Keyword(s):  
Additive Manufacturing ◽  
Complex Geometry ◽  
Cutting Tools ◽  
Manufacturing Processes ◽  
Layer By Layer ◽  
Advantages And Disadvantages ◽  
Finishing Processes ◽  
Short Time ◽  
Physical Phenomena ◽  
Am Processes

Recently, additive manufacturing (AM) processes have expanded rapidly in various fields of the industry because they offer design freedom, involve layer-by-layer construction from a computerized 3D model (minimizing material consumption), and allow the manufacture of parts with complex geometry (thus offering the possibility of producing custom parts). Also, they provide the advantage of a short time to make the final parts, do not involve the need for auxiliary resources (cutting tools, lighting fixtures or coolants) and have a low impact on the environment. However, the aspects that make these technologies not yet widely used in industry are poor surface quality of parts, uncertainty about the mechanical properties of products and low productivity. Research on the physical phenomena associated with additive manufacturing processes is necessary for proper control of the phenomena of melting, solidification, vaporization and heat transfer. This paper addresses the relevant additive manufacturing processes and their applications and analyzes the advantages and disadvantages of AM processes compared to conventional production processes. For the aerospace industry, these technologies offer possibilities for manufacturing lighter structures to reduce weight, but improvements in precision must be sought to eliminate the need for finishing processes.

Fresh in My Mind! Investigating the Effects of the Order of Presenting Opportunistic and Restrictive Design for Additive Manufacturing Content on Creativity

2020 ◽  
Author(s):  
Rohan Prabhu ◽  
Scarlett R. Miller ◽  
Timothy W. Simpson ◽  
Nicholas A. Meisel
Keyword(s):  
Additive Manufacturing ◽  
Self Efficacy ◽  
Engineering Students ◽  
Manufacturing Processes ◽  
Design For Additive Manufacturing ◽  
Undergraduate Engineering ◽  
Traditional Manufacturing ◽  
Order Of Presentation ◽  
Am Processes ◽  
Design For Am

Abstract Additive manufacturing (AM) processes present designers with creative freedoms beyond the capabilities of traditional manufacturing processes. However, to successfully leverage AM, designers must balance their creativity against the limitations inherent in these processes to ensure the feasibility of their designs. This feasible adoption of AM can be achieved if designers learn about and apply opportunistic and restrictive design for AM (DfAM) techniques at appropriate stages of the design process. Researchers have demonstrated the effect of the order of presentation of information on the learning and retrieval of said information; however, there is a need to explore this effect within DfAM education. In this paper, we explore this gap through an experimental study involving 195 undergraduate engineering students. Specifically, we compare two variations in DfAM education: (1) opportunistic DfAM followed by restrictive DfAM, and (2) restrictive DfAM followed by opportunistic DfAM, against only opportunistic DFAM and only restrictive DfAM training. These variations are compared through (1) differences in participants’ DfAM self-efficacy, (2) their self-reported DfAM use, and (3) the creativity of their design outcomes. From the results, we see that only students trained in opportunistic DfAM, with or without restrictive DfAM, present a significant increase in their opportunistic DfAM self-efficacy. However, all students trained in DfAM — opportunistic, restrictive, or both — demonstrated an increase in their restrictive DfAM self-efficacy. Further, we see that teaching restrictive DfAM first followed by opportunistic DfAM results in the generation of ideas with greater creativity — a novel research finding. These results highlight the need for educators to account for the effects of the order of presenting content to students, especially when educating students about DfAM.

scholarly journals The Design for Additive Manufacturing Worksheet

2017 ◽  
Vol 139 (10) ◽  
Author(s):  
Joran W. Booth ◽  
Jeffrey Alperovich ◽  
Pratik Chawla ◽  
Jiayan Ma ◽  
Tahira N. Reid ◽  
...  
Keyword(s):  
Additive Manufacturing ◽  
Prior Knowledge ◽  
Real World ◽  
High Volume ◽  
Visual Design ◽  
Design For Additive Manufacturing ◽  
Novice Users ◽  
The Cost ◽  
Am Processes

Additive manufacturing (AM) technologies have become integral to modern prototyping and manufacturing. Therefore, guidelines for using AM are necessary to help users new to the technology. Many others have proposed useful guidelines, but these are rarely written in a way that is accessible to novice users. Most guidelines (1) assume the user has extensive prior knowledge of the process, (2) apply to only a few AM technologies or a very specific application, or (3) describe benefits of the technology that novices already know. In this paper, we present a one-page, visual design for additive manufacturing worksheet for novice and intermittent users which addresses common mistakes as identified by various expert machinists and additive manufacturing facilities who have worked extensively with novices. The worksheet helps designers assess the potential quality of a part made using most AM processes and indirectly suggests ways to redesign it. The immediate benefit of the worksheet is to filter out bad designs before they are printed, thus saving time on manufacturing and redesign. We implemented this as a go-no-go test for a high-volume AM facility where users are predominantly novices, and we observed an 81% decrease in the rate of poorly designed parts. We also tested the worksheet in a classroom, but found no difference between the control and the experimental groups. This result highlights the importance of motivation since the cost of using AM in this context was dramatically lower than real-world costs. This second result highlights the limitations of the worksheet.

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 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.

scholarly journals Study of the Environmental Implications of Using Metal Powder in Additive Manufacturing and Its Handling

Metals ◽  
2020 ◽  
Vol 10 (2) ◽  
pp. 261 ◽  
Author(s):  
Jon Iñaki Arrizubieta ◽  
Olatz Ukar ◽  
Marta Ostolaza ◽  
Arantza Mugica
Keyword(s):  
Additive Manufacturing ◽  
Environmental Impact ◽  
Resource Use ◽  
Life Cycle Analysis ◽  
Chemical Compounds ◽  
Manufacturing Processes ◽  
Environmental Implications ◽  
Work Related ◽  
High Concentrations ◽  
Am Processes

Additive Manufacturing, AM, is considered to be environmentally friendly when compared to conventional manufacturing processes. Most researchers focus on resource consumption when performing the corresponding Life Cycle Analysis, LCA, of AM. To that end, the sustainability of AM is compared to processes like milling. Nevertheless, factors such as resource use, pollution, and the effects of AM on human health and society should be also taken into account before determining its environmental impact. In addition, in powder-based AM, handling the powder becomes an issue to be addressed, considering both the operator´s health and the subsequent management of the powder used. In view of these requirements, the fundamentals of the different powder-based AM processes were studied and special attention paid to the health risks derived from the high concentrations of certain chemical compounds existing in the typically employed materials. A review of previous work related to the environmental impact of AM is presented, highlighting the gaps found and the areas where deeper research is required. Finally, the implications of the reuse of metallic powder and the procedures to be followed for the disposal of waste are studied.

Additive Manufacturing Processes for Infrastructure Construction: A Review

2019 ◽  
Vol 141 (9) ◽  
Author(s):  
Abhinav Bhardwaj ◽  
Scott Z. Jones ◽  
Negar Kalantar ◽  
Zhijian Pei ◽  
John Vickers ◽  
...  
Keyword(s):  
Additive Manufacturing ◽  
Construction Industry ◽  
Manufacturing Sector ◽  
Manufacturing Processes ◽  
Current State ◽  
Industry Applications ◽  
Am Processes

Additive manufacturing (AM) has had an enormous impact on the manufacturing sector. Its role has evolved from printing prototypes to manufacturing functional parts for a variety of applications in the automotive, aerospace, and medical industries. Recently, AM processes have also been applied in the infrastructure construction industry. Applications of AM processes could bring in significant improvements in infrastructure construction, specifically in the areas of productivity and safety. It is desirable to have a review on the current state of emerging AM processes for infrastructure construction and existing gaps in this field. This paper reviews the AM processes in infrastructure construction. It discusses the process principle, application examples, and gaps for each of the AM processes.

scholarly journals Design of Additively Manufactured Structures for Biomedical Applications: A Review of the Additive Manufacturing Processes Applied to the Biomedical Sector

2019 ◽  
Vol 2019 ◽  
pp. 1-6 ◽  
Author(s):  
Flaviana Calignano ◽  
Manuela Galati ◽  
Luca Iuliano ◽  
Paolo Minetola
Keyword(s):  
Additive Manufacturing ◽  
Biomedical Applications ◽  
Point Of View ◽  
Disruptive Technology ◽  
Manufacturing Processes ◽  
Medical Field ◽  
Successful Case ◽  
Design Perspective ◽  
Manufacturing Techniques ◽  
Am Processes

Additive manufacturing (AM) is a disruptive technology as it pushes the frontier of manufacturing towards a new design perspective, such as the ability to shape geometries that cannot be formed with any other traditional technique. AM has today shown successful applications in several fields such as the biomedical sector in which it provides a relatively fast and effective way to solve even complex medical cases. From this point of view, the purpose of this paper is to illustrate AM technologies currently used in the medical field and their benefits along with contemporary. The review highlights differences in processes, materials, and design of additive manufacturing techniques used in biomedical applications. Successful case studies are presented to emphasise the potentiality of AM processes. The presented review supports improvements in materials and design for future researches in biomedical surgeries using instruments and implants made by AM.

scholarly journals Review of Tailoring Methods for Joints with Additively Manufactured Adherends and Adhesives

Materials ◽  
2020 ◽  
Vol 13 (18) ◽  
pp. 3949
Author(s):  
Mattia Frascio ◽  
Eduardo André de Sousa Marques ◽  
Ricardo João Camilo Carbas ◽  
Lucas Filipe Martins da Silva ◽  
Margherita Monti ◽  
...  
Keyword(s):  
Additive Manufacturing ◽  
Review Paper ◽  
State Of The Art ◽  
Manufacturing Processes ◽  
Bonded Joints ◽  
Design For Additive Manufacturing ◽  
Polymeric Additive ◽  
Current State ◽  
Bonded Joint ◽  
Current Modelling

This review aims to assess the current modelling and experimental achievements in the design for additive manufacturing of bonded joints, providing a summary of the current state of the art. To limit its scope, the document is focused only on polymeric additive manufacturing processes. As a result, this review paper contains a structured collection of the tailoring methods adopted for additively manufactured adherends and adhesives with the aim of maximizing bonded joint performance. The intent is, setting the state of the art, to produce an overview useful to identify the new opportunities provided by recent progresses in the design for additive manufacturing, additive manufacturing processes and materials’ developments.

Review: Dimensional Accuracy in Additive Manufacturing Processes

2014 ◽  
Author(s):  
Pil-Ho Lee ◽  
Haseung Chung ◽  
Sang Won Lee ◽  
Jeongkon Yoo ◽  
Jeonghan Ko
Keyword(s):  
Additive Manufacturing ◽  
State Of The Art ◽  
Dimensional Accuracy ◽  
The State ◽  
Manufacturing Processes ◽  
Accuracy Improvement ◽  
Process Characteristics ◽  
Art Research ◽  
Am Processes

This paper reviews the state-of-the-art research related to the dimensional accuracy in additive manufacturing (AM) processes. It is considered that the improvement of dimensional accuracy is one of the major scientific challenges to enhance the qualities of the products by AM. This paper analyzed the studies for commonly used AM techniques with respect to dimensional accuracy. These studies are classified by process characteristics, and relevant accuracy issues are examined. The accuracies of commercial AM machines are also listed. This paper also discusses suggestions for accuracy improvement. With the increase of the dimensional accuracy, not only the application of AM processes will diversify but also their value will increase.

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