Design Process Deconstructed: The Industry Case of an Elevator Button Assembly Redesigned for Additive Manufacturing

2019 ◽  
Author(s):  
Tuomas Puttonen
Keyword(s):  
Functional Analysis ◽  
Additive Manufacturing ◽  
Design Process ◽  
Efficient Design ◽  
3D Design ◽  
Design Methodologies ◽  
Current Design ◽  
Volume Product ◽  
End Use ◽  
Manufacturing Technologies

Abstract Additive manufacturing (AM) has during the 21st century gradually shifted from prototyping towards the manufacture of end-use quality parts. The drivers to utilize AM instead of conventional manufacturing methods are often linked to geometrical design freedom, increased performance, customization, part consolidation, and weight reduction. However, designers have struggled to take full advantage of these new capabilities. In part, this is due to a pervasive engineering mindset locked into the constraints of conventional manufacturing technologies. Another reason is the lack of efficient design methodologies that would take into account the new capabilities of AM. In this paper, to address the latter deficiency, an assembly redesign process for AM is deconstructed and analyzed. The studied assembly is an elevator accessibility button, which is a high-mix low-volume product. From the industry perspective, AM could reduce costs and increase the agility of production. Through systematic requirements mapping, part- and product-level functional analysis, a holistic functional analysis of the product is composed. The results of the product functional analysis are illustrated in a visual 3D design space. The 3D illustration is suggested as a conceptualization tool for the designers and as a way to reinforce creativity in the design process. The usability and expandability of the tool are discussed and contrasted with the current design methodologies for AM.

Software Development for Redesigning Bespoke Medical Products Obtained with Additive Manufacturing Technologies

2015 ◽  
Vol 772 ◽  
pp. 631-638
Author(s):  
Mihaela Elena Ulmeanu ◽  
Cristian Vasile Doicin ◽  
Daniel Cazacu ◽  
Corneliu Neagu
Keyword(s):  
Functional Analysis ◽  
Life Cycle ◽  
Additive Manufacturing ◽  
Product Life Cycle ◽  
Medical Product ◽  
Software Application ◽  
Surgical Guide ◽  
Medical Products ◽  
Custom Software ◽  
Manufacturing Technologies

This paper proposes a study on the development of automated custom software that uses the targeted functional analysis (TFA) methodology, in order to provide solutions for the optimal concept of bespoke medical products obtained with additive manufacturing (AM) technologies. The software, Custom-Med, provides a friendly Lab View interface and is easily adaptable for any single part medical product. The functional analysis uses tools like FAST diagrams, product life cycle analysis, technical and economic matrices. The study focuses on the functionality of the product throughout its life cycle, starting with development, production, usage, maintenance and finishing with storage or disposal. These become key input parameters when running Custom-Med. The main advantages brought by deploying a custom software application tool that uses the TFA methodology are: accurate technical parts, high quality, and customization for AM applications and reduced time for product development. Custom-Med is tested for validation purposes on three distinct medical products which are: a mandibular surgical guide, an adaptive ophthalmic speculum and vacuum surgical device. All three products are used for intraoperative surgical procedures.

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.

scholarly journals Machine Learning for Additive Manufacturing

Encyclopedia ◽  
2021 ◽  
Vol 1 (3) ◽  
pp. 576-588
Author(s):  
Dean Grierson ◽  
Allan E. W. Rennie ◽  
Stephen D. Quayle
Keyword(s):  
Machine Learning ◽  
Additive Manufacturing ◽  
Design Process ◽  
Manufacturing Processes ◽  
Wide Range ◽  
Production Techniques ◽  
End Use ◽  
Industrial Adoption ◽  
Further Development ◽  
Modelling Data

Additive manufacturing (AM) is the name given to a family of manufacturing processes where materials are joined to make parts from 3D modelling data, generally in a layer-upon-layer manner. AM is rapidly increasing in industrial adoption for the manufacture of end-use parts, which is therefore pushing for the maturation of design, process, and production techniques. Machine learning (ML) is a branch of artificial intelligence concerned with training programs to self-improve and has applications in a wide range of areas, such as computer vision, prediction, and information retrieval. Many of the problems facing AM can be categorised into one or more of these application areas. Studies have shown ML techniques to be effective in improving AM design, process, and production but there are limited industrial case studies to support further development of these techniques.

scholarly journals Shape and volume optimization of industrial parts

2022 ◽  
Vol 10 (1) ◽  
pp. 058-064
Author(s):  
Juraj Beniak ◽  
Miloš Matúš ◽  
Ľubomír Šooš ◽  
Peter Križan
Keyword(s):  
Additive Manufacturing ◽  
Strength Properties ◽  
Production Costs ◽  
Topological Optimization ◽  
Material Consumption ◽  
Great Pressure ◽  
End Use ◽  
Manufacturing Technologies ◽  
Original Part

In the present time, there are many challenges in the production of industrial parts. Due to the constantly rising prices of materials and energy, it is necessary to constantly look for ways to optimize production costs and optimize material consumption. There is great pressure on economical production, i. to produce products with the lowest costs given the expected and necessary properties. With the introduction of additive manufacturing technologies into practice and the production of parts for end use comes the introduction of methods for optimizing the shape of the part and the required amount of material for its production. We call this method Topological Optimization. The presented article describes the preparation of topologically optimized parts and a comparison of their strength properties with respect to the original and the original part.

scholarly journals Overview of Current Additive Manufacturing Technologies and Selected Applications

2012 ◽  
Vol 95 (3) ◽  
pp. 255-282 ◽  
Author(s):  
Timothy J. Horn ◽  
Ola L. A. Harrysson
Keyword(s):  
Additive Manufacturing ◽  
State Of The Art ◽  
Three Dimensional ◽  
New Paradigm ◽  
Three Dimensional Printing ◽  
The Past ◽  
Key Technologies ◽  
End Use ◽  
Manufacturing Technologies ◽  
Dimensional Printing

Three-dimensional printing or rapid prototyping are processes by which components are fabricated directly from computer models by selectively curing, depositing or consolidating materials in successive layers. These technologies have traditionally been limited to the fabrication of models suitable for product visualization but, over the past decade, have quickly developed into a new paradigm called additive manufacturing. We are now beginning to see additive manufacturing used for the fabrication of a range of functional end use components. In this review, we briefly discuss the evolution of additive manufacturing from its roots in accelerating product development to its proliferation into a variety of fields. Here, we focus on some of the key technologies that are advancing additive manufacturing and present some state of the art applications.

scholarly journals Product Design by Additive Manufacturing for Water Environments: Study of Degradation and Absorption Behavior of PLA and PETG

Polymers ◽  
2021 ◽  
Vol 13 (7) ◽  
pp. 1036
Author(s):  
Daniel Moreno Nieto ◽  
María Alonso-García ◽  
Miguel-Angel Pardo-Vicente ◽  
Lucía Rodríguez-Parada
Keyword(s):  
Additive Manufacturing ◽  
Product Design ◽  
Control Sample ◽  
Polymeric Materials ◽  
Degradation Process ◽  
Fused Filament Fabrication ◽  
End Use ◽  
Definition Of ◽  
Manufacturing Technologies ◽  
Saturated Solutions

Additive manufacturing technologies are shifting from rapid prototyping technologies to end use or final parts production. Polymeric material extrusion processes have been broadly addressed with a specific definition of all parameters and variables for all different of technologies approaches and materials. Recycled polymeric materials have been studied due to the growing importance of the environmental awareness of the contemporary society. Beside this, little specific research has been found in product development applications for AM where the printed parts are in highly moisture environments or surrounded by water, but polymers have been for long used in such industries with conventional manufacturing approaches. This work focuses on the analysis and comparison of two different additively manufactured polymers printed by fused filament fabrication (FFF) processes using desktop-size printers to be applied for product design. The polymers used have been a recycled material: polyethylene terephthalate glycol (PETG) and polylactic acid (PLA). Degradation and water absorption behaviors of both materials are presented, analyzed and discussed in this paper, where different samples have been immersed in saturated solutions of water with maritime salt and sugar together with a control sample immersed in distilled water. The samples have been dimensionally and weight-controlled weekly as well as microscopically analyzed to understand degradation and absorption processes that appear in the fully saturated solutions. The results revealed how the absorption process is stabilized after a reduced number of weeks for both materials and how the degradation process is more remarked in the PLA material due to its organic nature.

scholarly journals A STRUCTURED APPROACH TO REDUCE DESIGN ITERATIONS IN ADDITIVE MANUFACTURING

2021 ◽  
Vol 1 ◽  
pp. 231-240
Author(s):  
Laura Wirths ◽  
Matthias Bleckmann ◽  
Kristin Paetzold
Keyword(s):  
Additive Manufacturing ◽  
Spare Parts ◽  
Design Guidelines ◽  
Final Part ◽  
Layer By Layer ◽  
Powder Bed ◽  
Batch Sizes ◽  
Manufacturing Technologies ◽  
Structured Approach ◽  
Design Freedom

AbstractAdditive Manufacturing technologies are based on a layer-by-layer build-up. This offers the possibility to design complex geometries or to integrate functionalities in the part. Nevertheless, limitations given by the manufacturing process apply to the geometric design freedom. These limitations are often unknown due to a lack of knowledge of the cause-effect relationships of the process. Currently, this leads to many iterations until the final part fulfils its functionality. Particularly for small batch sizes, producing the part at the first attempt is very important. In this study, a structured approach to reduce the design iterations is presented. Therefore, the cause-effect relationships are systematically established and analysed in detail. Based on this knowledge, design guidelines can be derived. These guidelines consider process limitations and help to reduce the iterations for the final part production. In order to illustrate the approach, the spare parts production via laser powder bed fusion is used as an example.

scholarly journals Adhesion Studies during Generative Hybridization of Textile-Reinforced Thermoplastic Composites via Additive Manufacturing

Materials ◽  
2021 ◽  
Vol 14 (14) ◽  
pp. 3888
Author(s):  
Johanna Maier ◽  
Christian Vogel ◽  
Tobias Lebelt ◽  
Vinzenz Geske ◽  
Thomas Behnisch ◽  
...  
Keyword(s):  
Additive Manufacturing ◽  
Polyamide 6 ◽  
Thermoplastic Composites ◽  
Efficient Production ◽  
Angle Measurements ◽  
Small Series ◽  
Contact Angle Measurements ◽  
Static Tensile ◽  
Pre Treatment ◽  
Manufacturing Technologies

Generative hybridization enables the efficient production of lightweight structures by combining classic manufacturing processes with additive manufacturing technologies. This type of functionalization process allows components with high geometric complexity and high mechanical properties to be produced efficiently in small series without the need for additional molds. In this study, hybrid specimens were generated by additively depositing PA6 (polyamide 6) via fused layer modeling (FLM) onto continuous woven fiber GF/PA6 (glass fiber/polyamide 6) flat preforms. Specifically, the effects of surface pre-treatment and process-induced surface interactions were investigated using optical microscopy for contact angle measurements as well as laser profilometry and thermal analytics. The bonding characteristic at the interface was evaluated via quasi-static tensile pull-off tests. Results indicate that both the bond strength and corresponding failure type vary with pre-treatment settings and process parameters during generative hybridization. It is shown that both the base substrate temperature and the FLM nozzle distance have a significant influence on the adhesive tensile strength. In particular, it can be seen that surface activation by plasma can significantly improve the specific adhesion in generative hybridization.

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