Nowadays, due to rapid prototyping processes improvements, a functional metal part can be built directly by Additive Manufacturing. It is now accepted that these new processes can increase productivity while enabling a mass and cost reduction and an increase of the parts functionality. However, the physical phenomena that occur during these processes have a strong impact on the quality of the produced parts. Especially, because the manufacturing paths used to produce the parts lead these physical phenomena,

Cleaner production and sustainability are of crucial importance in the field of manufacturing processes where great amounts of energy and materials are being consumed. Nowadays, additive manufacturing technologies such as Direct Additive Laser Manufacturing allow us to manufacture functional products with high added value. Insofar as environmental considerations become an important issue in our society, as well as legislation regarding environment become prominent (Normalization ISO 14 044), the environmental impact of those processes have to be evaluated in order to make easier its acceptance in the industrial world. Some studies have been conducted on electric consumption of machine tools (stand-by consumption, in process consumption, etc) but only a few studies take into account the whole existing environmental flows (material, fluids, electricity). This paper presents a new methodology where all flows consumed (material, fluids, electricity) are considered in the environmental impact assessment. This method coupled a global view required in a sustainable approach and an accurate evaluation of flows consumption in the machine. The methodology developed is based on a predictive model of flows consumption defined from the manufacturing path and CAD model of the part which will be produce. In order to get an accurate model of the process, each feature of the machine is modeled. The goal of this work is to integrate this model into the design loop for additive manufacturing parts.

International audienceAdditive Manufacturing is an innovative way to produce parts. However its environmental impact is unknown. To ensure the development of additive manufacturing processes it seems important to develop the concept of DFSAM (Design for Sustainable Additive Manufacturing). In fact, one of the objectives of environmental sustainable manufacturing is to minimize the whole flux consumption (electricity, material and fluids) during manufacturing step. To achieve this goal, it is interesting to get a predictive model of consumptions, integrated in the design step, allowing to evaluate the product's environmental impact during the manufacturing step. This paper presents a new methodology for electric, fluids and raw material consumptions assessment for additive manufacturing processes, in particular for a direct metal deposition process. The methodology will help engineers to design parts optimized for additive manufacturing with an environmental point of view

Design For Manufacturing (DFM) approaches aim to integrate manufacturability aspects during the design stage. Most of DFM approaches usually consider only one manufacturing process, but products competitiveness may be improved by designing hybrid modular products, in which products are seen as 3-D puzzles with modules realized aside by the best manufacturing process and further gathered. A new DFM system is created in order to give quantitative information during the product design stage of which modules will benefit in being machined and which ones will advantageously be realized by an additive process (such as Selective Laser Sintering or laser deposition). A methodology for a manufacturability evaluation in case of a subtractive or an additive manufacturing process is developed and implemented in a CAD software. Tests are carried out on industrial products from automotive industry

International audienceNowadays, due to rapid prototyping processes improvements, a functional part can be built directly through additive manufacturing. It is now accepted that these new processes can increase productivity while enabling a mass and cost reduction and an increase of the parts functionality. However, in order to achieve this, new design methods have to be developed to take into account the specificities of these processes, with the Design For Additive Manufacturing (DFAM) concept. In this context, a methodology to obtain a suitable design of parts built through additive manufacturing is proposed ; both design requirements and manufacturing constraints are taken into account