scholarly journals Investigating the Gap between Research and Practice in Additive Manufacturing

2021 ◽  
Author(s):  
Jennifer Bracken ◽  
Zachary Bentley ◽  
James Meye ◽  
Erik Miller ◽  
Jablokow Kathryn W. ◽  
...  
Keyword(s):  
Additive Manufacturing ◽  
Idea Generation ◽  
Concept Generation ◽  
Technical Problems ◽  
Before And After ◽  
Implementation Time ◽  
Design Objects ◽  
Traditional Manufacturing ◽  
Commercial Organization ◽  
Am Processes

Additive manufacturing (AM) provides opportunities to design objects differently than traditional manufacturing methods allow, but only if designers understand the possibilities AM presents. In this study, we examined whether an AM workshop combined with an idea generation session could inspire engineering professionals to use AM solutions to solve current technical problems they face. All subjects were employees at an organization that will be referred to as Company X, a multinational commercial organization based in North America. During the study, we collected ideas for 24 projects generated before and after a training workshop focused on design for AM. In the workshop, we provided three hours of instruction about design for two metal-based AM processes. The participants’ ideas were assessed using four specific metrics: (1) cost, (2) time,(3) completeness of solution, and (4) quality, which was a function of feasibility, usefulness, and novelty. Using these data, we explored whether the workshop was effective in inspiring the participants to use AM methods and techniques from AM research in their concept generation and whether participants’ AM solutions showed improvement in cost, implementation time, and quality over non-AM designs generated before the workshop.

scholarly journals Investigation of microstructure and hardness of a rib geometry produced by metal forming and wire-arc additive manufacturing

2018 ◽  
Vol 190 ◽  
pp. 02005 ◽  
Author(s):  
Markus Hirtler ◽  
Angelika Jedynak ◽  
Benjamin Sydow ◽  
Alexander Sviridov ◽  
Markus Bambach
Keyword(s):  
Additive Manufacturing ◽  
Metal Forming ◽  
Batch Size ◽  
Unit Costs ◽  
Batch Sizes ◽  
Traditional Manufacturing ◽  
Manufacturing Technologies ◽  
Forming Tools ◽  
Wire Arc Additive Manufacturing ◽  
Am Processes

Within the scope of consumer-oriented production, individuality and cost-effectiveness are two essential aspects, which can barely be met by traditional manufacturing technologies. Conventional metal forming techniques are suitable for large batch sizes. If variants or individualized components have to be formed, the unit costs rise due to the inevitable tooling costs. For such applications, additive manufacturing (AM) processes, which do not require tooling, are more suitable. Due to the low production rates and limited build space of AM machines, the manufacturing costs are highly dependent on part size and batch size. Hence, a combination of both manufacturing technologies i.e. conventional metal forming and additive manufacturing seems expedient for a number of applications. The current study develops a process chain combining forming and additive manufacturing. First, a semi-finished product is formed with forming tools of reduced complexity and then finished by additive manufacturing. This research investigates the addition of features using AlSi12 created by Wire Arc Additive Manufacturing (WAAM) on formed EN-AW 6082 preforms. By forming, the strength of the material was increased, while this effect was partly reduced by the heat input of the WAAM process.

Favoring Complexity: A Mixed Methods Exploration of Factors That Influence Concept Selection When Designing for Additive Manufacturing

2021 ◽  
Vol 143 (10) ◽  
Author(s):  
Rohan Prabhu ◽  
Rainmar L. Leguarda ◽  
Scarlett R. Miller ◽  
Timothy W. Simpson ◽  
Nicholas A. Meisel
Keyword(s):  
Additive Manufacturing ◽  
Selection Process ◽  
Solution Space ◽  
Idea Generation ◽  
Concept Selection ◽  
Stage Design ◽  
Four Dimensions ◽  
Build Time ◽  
Traditional Manufacturing ◽  
Selection Stage

Abstract The capabilities of additive manufacturing (AM) open up designers’ solution space and enable them to build designs previously impossible through traditional manufacturing (TM). To leverage this design freedom, designers must emphasize opportunistic design for AM (DfAM), i.e., design techniques that leverage AM capabilities. Additionally, designers must also emphasize restrictive DfAM, i.e., design considerations that account for AM limitations, to ensure that their designs can be successfully built. Therefore, designers must adopt a “dual” design mindset—emphasizing both, opportunistic and restrictive DfAM—when designing for AM. However, to leverage AM capabilities, designers must not only generate creative ideas for AM but also select these creative ideas during the concept selection stage. Design educators must specifically emphasize selecting creative ideas in DfAM, as ideas perceived as infeasible through the traditional design for manufacturing lens may now be feasible with AM. This emphasis could prevent creative but feasible ideas from being discarded due to their perceived infeasibility. While several studies have discussed the role of DfAM in encouraging creative idea generation, there is a need to investigate concept selection in DfAM. In this paper, we investigated the effects of four variations in DfAM education: (1) restrictive, (2) opportunistic, (3) restrictive followed by opportunistic (R-O), and (4) opportunistic followed by restrictive (O-R), on students’ concept selection process. We compared the creativity of the concepts generated by students to the creativity of the concepts they selected. The creativity of designs was measured on four dimensions: (1) uniqueness, (2) usefulness, (3) technical goodness, and (4) overall creativity. We also performed qualitative analyses to gain insight into the rationale provided by students when making their design decisions. From the results, we see that only teams from the restrictive and dual O-R groups selected ideas of higher uniqueness and overall creativity. In contrast, teams from the dual R-O DfAM group selected ideas of lower uniqueness compared with the mean uniqueness of ideas generated. Finally, we see that students trained in opportunistic DfAM emphasized minimizing build material the most, whereas those trained only in restrictive DfAM emphasized minimizing build time. These results highlight the need for DfAM education to encourage AM designers to not just generate creative ideas but also have the courage to select them for the next stage of design.

Favoring Complexity: A Mixed Methods Exploration of Factors That Influence Concept Selection in Design for Additive Manufacturing

2020 ◽  
Author(s):  
Rohan Prabhu ◽  
Rainmar L. Leguarda ◽  
Scarlett R. Miller ◽  
Timothy W. Simpson ◽  
Nicholas A. Meisel
Keyword(s):  
Additive Manufacturing ◽  
Selection Process ◽  
Solution Space ◽  
Idea Generation ◽  
Concept Selection ◽  
Educational Groups ◽  
Early Design Stages ◽  
Traditional Manufacturing ◽  
Design For Am

Abstract The capabilities of additive manufacturing (AM) open up designers’ solution space and enable them to build designs previously impossible through traditional manufacturing. To leverage AM, designers must not only generate creative ideas, but also propagate these ideas without discarding them in the early design stages. This emphasis on selecting creative ideas is particularly important in design for AM (DfAM), as ideas perceived as infeasible through the traditional design for manufacturing lens could now be feasible with AM. Several studies have discussed the role of DfAM in encouraging creative idea generation; however, there is a need to understand concept selection in DfAM. In this paper, we investigated the effect of two variations in DfAM education: 1) restrictive DfAM and 2) dual DfAM (opportunistic and restrictive) on students’ concept selection process. Specifically, we compared the creativity of the concepts generated by the students to the creativity of the concepts selected by them. Further, we performed qualitative analyses to explore the rationale provided by the students in making these design decisions. From the results, we see that teams from both educational groups select ideas of greater usefulness; however, only teams from the restrictive DfAM group select ideas of higher uniqueness and overall creativity. Further, we see that introducing students to opportunistic DfAM increases their emphasis on the complexity of designs when evaluating and selecting them. These results highlight the need for DfAM education to encourage AM designers to not just generate but also select creative ideas.

A Review on Process Monitoring and Control in Metal-Based Additive Manufacturing

2014 ◽  
Vol 136 (6) ◽  
Author(s):  
Gustavo Tapia ◽  
Alaa Elwany
Keyword(s):  
Additive Manufacturing ◽  
Process Monitoring ◽  
Monitoring And Control ◽  
Part Quality ◽  
Industrial Sectors ◽  
Process Monitoring And Control ◽  
Traditional Manufacturing ◽  
Manufacturing Technologies ◽  
And Control ◽  
Am Processes

There is consensus among both the research and industrial communities, and even the general public, that additive manufacturing (AM) processes capable of processing metallic materials are a set of game changing technologies that offer unique capabilities with tremendous application potential that cannot be matched by traditional manufacturing technologies. Unfortunately, with all what AM has to offer, the quality and repeatability of metal parts still hamper significantly their widespread as viable manufacturing processes. This is particularly true in industrial sectors with stringent requirements on part quality such as the aerospace and healthcare sectors. One approach to overcome this challenge that has recently been receiving increasing attention is process monitoring and real-time process control to enhance part quality and repeatability. This has been addressed by numerous research efforts in the past decade and continues to be identified as a high priority research goal. In this review paper, we fill an important gap in the literature represented by the absence of one single source that comprehensively describes what has been achieved and provides insight on what still needs to be achieved in the field of process monitoring and control for metal-based AM processes.

scholarly journals Engineering and Economic Aspects of Additive Manufacturing in Energy Related Industries

2020 ◽  
Author(s):  
Sandip Dutta ◽  
Sagar Dasgupta ◽  
Geetha Chimata
Keyword(s):  
Additive Manufacturing ◽  
Complex Geometry ◽  
Production Methods ◽  
Energy Applications ◽  
Recent Developments ◽  
Subtractive Manufacturing ◽  
Manufacturing Methods ◽  
Manufacturing Techniques ◽  
Traditional Manufacturing ◽  
Am Processes

Additive manufacturing is the buzz word these days and many companies are leaning on this technology to leap forward in un-chartered design space that promises to give better performance at impossible to reach design goals with the current manufacturing methods. This paper addresses recent developments that have occurred in Energy related businesses with the adoption of 3D printing, also known as Additive Manufacturing (AM). It covers what and why of additive manufacturing; what constitutes energy and AM industry; current activities in AM for energy; AM for different energy sectors; AM processes; AM applications; selected patents in additive manufacturing associated with energy applications; and economic and financial aspects of AM in energy related industries. In this review paper it was noted that in-spite of phenomenal growth in AM, it seldom replaces traditional production methods due to associated constraints. Many companies are finding complimentary AM processes along with subtractive manufacturing techniques to meet the market demands. However, AM is particularly advantageous and attractive compared to traditional manufacturing methods for low volume complex geometry parts.

scholarly journals The Corrosion of Stainless Steel Made by Additive Manufacturing: A Review

Metals ◽  
2021 ◽  
Vol 11 (3) ◽  
pp. 516
Author(s):  
Gyeongbin Ko ◽  
Wooseok Kim ◽  
Kyungjung Kwon ◽  
Tae-Kyu Lee
Keyword(s):  
Stainless Steel ◽  
Additive Manufacturing ◽  
Relevant Literature ◽  
Corrosion Property ◽  
Corrosion Study ◽  
Direct Laser ◽  
Manufacturing Methods ◽  
Traditional Manufacturing ◽  
Wire Arc Additive Manufacturing ◽  
Am Processes

The advantages of additive manufacturing (AM) of metals over traditional manufacturing methods have triggered many relevant studies comparing the mechanical properties, corrosion behavior, and microstructure of metals produced by AM or traditional manufacturing methods. This review focuses exclusively on the corrosion property of AM-fabricated stainless steel by comprehensively analyzing the relevant literature. The principles of various AM processes, which have been adopted in the corrosion study of stainless steel, and the corrosion behaviors of stainless steel depending on the AM process, the stainless steel type, and the corrosion environment are summarized. In this comprehensive analysis of relevant literature, we extract dominant experimental factors and the most relevant properties affecting the corrosion of AM-fabricated stainless steel. In selective laser melting, the effects of the scan speed, laser power, energy density, and the post-treatment technologies are usually investigated. In direct laser deposition, the most relevant papers focused on the effect of heat treatments on passive films and the Cr content. There has been no specific trend in the corrosion study of stainless steel that is fabricated by other AM processes, such as wire arc additive manufacturing. Given the rising utilization of AM-produced metal parts, the corrosion issue will be more important in the future, and this review should provide a worthwhile basis for future works.

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.

Investigating the Role of Geometric Dimensioning and Tolerancing in Additive Manufacturing

2015 ◽  
Vol 137 (11) ◽  
Author(s):  
Gaurav Ameta ◽  
Robert Lipman ◽  
Shawn Moylan ◽  
Paul Witherell
Keyword(s):  
Additive Manufacturing ◽  
Tolerance Analysis ◽  
Geometric Accuracy ◽  
Geometric Dimensioning And Tolerancing ◽  
Dimensioning And Tolerancing ◽  
Internal Cavities ◽  
Functional Features ◽  
Traditional Manufacturing ◽  
Am Processes

Additive manufacturing (AM) has increasingly gained attention in the last decade as a versatile manufacturing process for customized products. AM processes can create complex, freeform shapes while also introducing features, such as internal cavities and lattices. These complex geometries are either not feasible or very costly with traditional manufacturing processes. The geometric freedoms associated with AM create new challenges in maintaining and communicating dimensional and geometric accuracy of parts produced. This paper reviews the implications of AM processes on current geometric dimensioning and tolerancing (GD&T) practices, including specification standards, such as ASME Y14.5 and ISO 1101, and discusses challenges and possible solutions that lie ahead. Various issues highlighted in this paper are classified as (a) AM-driven specification issues and (b) specification issues highlighted by the capabilities of AM processes. AM-driven specification issues may include build direction, layer thickness, support structure related specification, and scan/track direction. Specification issues highlighted by the capabilities of AM processes may include region-based tolerances for complex freeform surfaces, tolerancing internal functional features, and tolerancing lattice and infills. We introduce methods to address these potential specification issues. Finally, we summarize potential impacts to upstream and downstream tolerancing steps, including tolerance analysis, tolerance transfer, and tolerance evaluation.

scholarly journals Additive Manufacturing of Polymer Materials: Progress, Promise and Challenges

Polymers ◽  
2021 ◽  
Vol 13 (5) ◽  
pp. 753
Author(s):  
Saad Saleh Alghamdi ◽  
Sabu John ◽  
Namita Roy Choudhury ◽  
Naba K. Dutta
Keyword(s):  
Additive Manufacturing ◽  
Shape Memory Polymers ◽  
Polymeric Materials ◽  
Polymer Materials ◽  
Research Needs ◽  
Future Perspectives ◽  
Responsive Materials ◽  
Manufacturing Method ◽  
Traditional Manufacturing ◽  
Am Processes

The use of additive manufacturing (AM) has moved well beyond prototyping and has been established as a highly versatile manufacturing method with demonstrated potential to completely transform traditional manufacturing in the future. In this paper, a comprehensive review and critical analyses of the recent advances and achievements in the field of different AM processes for polymers, their composites and nanocomposites, elastomers and multi materials, shape memory polymers and thermo-responsive materials are presented. Moreover, their applications in different fields such as bio-medical, electronics, textiles, and aerospace industries are also discussed. We conclude the article with an account of further research needs and future perspectives of AM process with polymeric materials.

scholarly journals Additive Manufacturing and Big Data

2016 ◽  
Vol 1 (3) ◽  
pp. 107-121 ◽  
Author(s):  
Lidong Lidong ◽  
Cheryl Ann Alexander
Keyword(s):  
Big Data ◽  
Additive Manufacturing ◽  
Supply Chains ◽  
Data Analytics ◽  
Big Data Analytics ◽  
Manufacturing Processes ◽  
Geometric Shapes ◽  
Traditional Manufacturing ◽  
Am Processes

Additive manufacturing (AM) can produce parts with complex geometric shapes and reduce material use and weight. However, there are limited materials available for AM processes; the speed of production is slower compared with traditional manufacturing processes. Big Data analytics helps analyze AM processes and facilitate AM in impacting supply chains. This paper introduces advantages, applications, and technology progress of AM. Cybersecurity in AM and barriers to broad adoption of AM are discussed. Big data in AM and Big Data analytics for AM are also presented.

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