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.

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.

scholarly journals Assembly Based Methods to Support Product Innovation in Design for Additive Manufacturing: An Exploratory Case Study

2015 ◽  
Vol 137 (12) ◽  
Author(s):  
Floriane Laverne ◽  
Frédéric Segonds ◽  
Nabil Anwer ◽  
Marc Le Coq
Keyword(s):  
Additive Manufacturing ◽  
Product Innovation ◽  
Idea Generation ◽  
Generation Process ◽  
Design For Additive Manufacturing ◽  
Design Features ◽  
Systemic Level ◽  
Product Manufacturing

Additive manufacturing (AM) is emerging as an important manufacturing process and a key technology for enabling innovative product development. Design for additive manufacturing (DFAM) is nowadays a major challenge to exploit properly the potential of AM in product innovation and product manufacturing. However, in recent years, several DFAM methods have been developed with various design purposes. In this paper, we first present a state-of-the-art overview of the existing DFAM methods, then we introduce a classification of DFAM methods based on intermediate representations (IRs) and product's systemic level, and we make a comparison focused on the prospects for product innovation. Furthermore, we present an assembly based DFAM method using AM knowledge during the idea generation process in order to develop innovative architectures. A case study demonstrates the relevance of such approach. The main contribution of this paper is an early DFAM method consisting of four stages as follows: choice and development of (1) concepts, (2) working principles, (3) working structures, and (4) synthesis and conversion of the data in design features. This method will help designers to improve their design features, by taking into account the constraints of AM in the early stages.

Structural Optimization and Additive Manufacturing

2014 ◽  
Vol 611-612 ◽  
pp. 811-817 ◽  
Author(s):  
Julen Ibabe ◽  
Antero Jokinen ◽  
Jari Larkiola ◽  
Gurutze Arruabarrena
Keyword(s):  
Mechanical Properties ◽  
Finite Element ◽  
Stainless Steel ◽  
Additive Manufacturing ◽  
Structural Optimization ◽  
Finite Element Simulations ◽  
Optimization Process ◽  
Manufacturing Processes ◽  
Complex Geometries ◽  
Additive Manufacturing Technology

Additive Manufacturing technology offers almost unlimited capacity when manufacturing parts with complex geometries which could be impossible to get with conventional manufacturing processes. This paper is based on the study of a particular real part which has been redesigned and manufactured using an AM process. The challenge consists of redesigning the geometry of an originally aluminium made part, in order to get a new stainless steel made model with same mechanical properties but with less weight. The new design is the result of a structural optimization process based on Finite Element simulations which is carried out bearing in mind the facilities that an AM process offers.

Lattice Structure Design for Additive Manufacturing: Unit Cell Topology Optimization

2019 ◽  
Author(s):  
Bradley Hanks ◽  
Mary Frecker
Keyword(s):  
Topology Optimization ◽  
Additive Manufacturing ◽  
Lattice Structure ◽  
Optimization Method ◽  
Structure Design ◽  
Unit Cell ◽  
Lattice Structures ◽  
Design For Additive Manufacturing ◽  
Structure Topology

Abstract Additive manufacturing is a developing technology that enhances design freedom at multiple length scales, from the macroscale, or bulk geometry, to the mesoscale, such as lattice structures, and even down to tailored microstructure. At the mesoscale, lattice structures are often used to replace solid sections of material and are typically patterned after generic topologies. The mechanical properties and performance of generic unit cell topologies are being explored by many researchers but there is a lack of development of custom lattice structures, optimized for their application, with considerations for design for additive manufacturing. This work proposes a ground structure topology optimization method for systematic unit cell optimization. Two case studies are presented to demonstrate the approach. Case Study 1 results in a range of unit cell designs that transition from maximum thermal conductivity to minimization of compliance. Case Study 2 shows the opportunity for constitutive matching of the bulk lattice properties to a target constitutive matrix. Future work will include validation of unit cell modeling, testing of optimized solutions, and further development of the approach through expansion to 3D and refinement of objective, penalty, and constraint functions.

Development of Technical Creativity Featuring Modified TRIZ-AM Inventive Principle to Support Additive Manufacturing

2021 ◽  
pp. 1-47
Author(s):  
Siti Nur Humaira Mazlan ◽  
Aini Zuhra Abdul Kadir ◽  
Mariusz Deja ◽  
Dawid Zielinski ◽  
Mohd Rizal Alkahari
Keyword(s):  
Additive Manufacturing ◽  
Problem Solving ◽  
Product Design ◽  
Design For Additive Manufacturing ◽  
Technical Creativity ◽  
Design Methodologies ◽  
Creative Solutions ◽  
Design Freedom ◽  
Early Phases

Abstract The design for additive manufacturing (DFAM) processing was introduced to fully utilise the design freedom provided by additive manufacturing (AM). Consequently, appropriate design methodologies have become essential for this technology. Recently, many studies have identified the importance of DFAM method utilisation to produce AM parts, and TRIZ is a strategy used to formalise design methodologies. TRIZ is a problem-solving tool developed to assist designers to find innovative and creative solutions. However, the pathway for synergising TRIZ and DFAM is not clearly explained with respect to AM capabilities and complexities. This is mainly because most methods continue to involve use of the classical TRIZ principle, which was developed early in 1946, 40 years before AM technologies were introduced in the mid-1980s. Therefore, to tackle this issue, this study aims to enhance the 40 principles of classical TRIZ to accommodate AM design principles. A modified TRIZ-AM principle has been developed to define the pathway to AM solutions. TRIZ-AM cards are tools that assist designers to select inventive principles (IPs) in the early phases of product design and development. The case study illustrates that even inexperienced AM users can creatively design innovative AM parts.

TOWARD EFFECTIVE AND EFFICIENT PROCESS IN PROJECT VALIDATION

2015 ◽  
Vol 2 (1) ◽  
Author(s):  
Arie Gottfried ◽  
Paolo Piantanida
Keyword(s):  
Verification And Validation ◽  
Public Works ◽  
Design Phase ◽  
Urban Center ◽  
Validation Process ◽  
First Case ◽  
Early Validation ◽  
European Regulations ◽  
Pros And Cons

In Italy, following the introduction of European regulations and the updating of the national legislation on public works, the project verification and validation play a strategic rule in reducing problems and variation issues at each design phase and during the completion stage. We have the opportunity of a behind-the-scenes journey considering two early validation experiences in Italy and the phase following their tender of bidding. The first case study is the “Progetto Raddoppio” for the Politecnico di Torino, that is to say the project of extension works of the buildings for Departments and lecture halls in Turin Polytechnic: these works went to an end, and now we can evaluate pros and cons of that early validation experience on the works management and on the built product. The second case is the “Urban Center” commissioned by Comune di Torino, a large exhibition area coming from a deep renovation of the buildings formerly “Officine grandi riparazioni ferroviarie” (Railways Heavy Reparation Works). In this case, the works never begun, but the validation process was completed and some issues arisen.

scholarly journals A design for additive manufacturing case study: fingerprint stool on a BigRep ONE

2019 ◽  
Vol 25 (6) ◽  
pp. 1069-1079 ◽  
Author(s):  
James I. Novak ◽  
Jonathon O’Neill
Keyword(s):  
Additive Manufacturing ◽  
Large Scale ◽  
Future Research ◽  
Design For Additive Manufacturing ◽  
Fused Filament Fabrication ◽  
Content Type ◽  
Layer Height ◽  
Design Engineers ◽  
Final Design

Purpose This paper aims to present new qualitative and quantitative data about the recently released “BigRep ONE” 3 D printer led by the design of a one-off customized stool. Design/methodology/approach A design for additive manufacturing (DfAM) framework was adopted, with simulation data iteratively informing the final design. Findings Process parameters can vary manufacturing costs of a stool by over AU$1,000 and vary print time by over 100 h. Following simulation, designers can use the knowledge to inform iteration, with a second variation of the design being approximately 50 per cent cheaper and approximately 50 per cent faster to manufacture. Metrology data reveal a tolerance = 0.342 per cent in overall dimensions, and surface roughness data are presented for a 0.5 mm layer height. Research limitations/implications Led by design, this study did not seek to explore the full gamut of settings available in slicing software, focusing predominantly on nozzle diameter, layer height and number of walls alongside the recommended settings from BigRep. The study reveals numerous areas for future research, including more technical studies. Practical implications When knowledge and techniques from desktop 3 D printing are scaled up to dimensions measuring in meters, new opportunities and challenges are presented for design engineers. Print times and material costs in particular are scaled up significantly, and this study provides numerous considerations for research centers, 3 D printing bureaus and manufacturers considering large-scale fused filament fabrication manufacturing. Originality/value This is the first peer-reviewed study involving the BigRep ONE, and new knowledge is presented about the practical application of the printer through a design-led project. Important relationships between material volume/cost and print time are valuable for early adopters.

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