A Design Framework for Additive Manufacturing: Integration of Additive Manufacturing Capabilities in the Early Design Process

Renjith, Sarath C.; Park, Kijung; Kremer, Gül E. Okudan

doi:10.1007/s12541-019-00253-3

Cited by 71 publications

(39 citation statements)

References 55 publications

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“…Additive manufacturing (AM) technologies produce threedimensional (3D) physical objects from digital information through layer-by-layer, line-by-line, piece-by-piece, or surface-by-surface depositions of materials on the substrate and the previous layer [1][2][3][4][5]. The AM is defined to be "a process of joining materials to make parts from 3D model data, usually layer upon layer, as opposed to subtractive manufacturing and formative manufacturing methodologies" by ASTM and ISO standards [1,6,7].…”

Section: Introductionmentioning

confidence: 99%

Directed Energy Deposition (DED) Process: State of the Art

Ahn

2021

Int. J. of Precis. Eng. and Manuf.-Green Tech.

368

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Metal additive manufacturing technologies, such as powder bed fusion process, directed energy deposition (DED) process, sheet lamination process, etc., are one of promising flexible manufacturing technologies due to direct fabrication characteristics of a metallic freeform with a three-dimensional shape from computer aided design data. DED processes can create an arbitrary shape on even and uneven substrates through line-by-line deposition of a metallic material. Theses DED processes can easily fabricate a heterogeneous material with desired properties and characteristics via successive and simultaneous depositions of different materials. In addition, a hybrid process combining DED with different manufacturing processes can be conveniently developed. Hence, researches on the DED processes have been steadily increased in recent years. This paper reviewed recent research trends of DED processes and their applications. Principles, key technologies and the state-of-the art related to the development of process and system, the optimization of deposition conditions and the application of DED process were discussed. Finally, future research issues and opportunities of the DED process were identified.

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Section: Introductionmentioning

confidence: 99%

Directed Energy Deposition (DED) Process: State of the Art

Ahn

2021

Int. J. of Precis. Eng. and Manuf.-Green Tech.

368

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“…The potential benefits of DAM have already been studied by researchers [24][25][26]. Some of the most important benefits of DAM are: (1) Design freedom [27], (2) Short lead times [28], (3) Low start up-costs [29]. Although DAM with shorter lead times and decreased total production costs may be considered as an alternative to the traditional manufacturing technologies, it has some limitations which challenge the use of DAM as a manufacturing method even for short series productions [10,26,30].…”

Section: Benefits and Limitations Of Dammentioning

confidence: 99%

Assessing the Suitability of Freeform Injection Molding for Low Volume Injection Molded Parts: A Design Science Approach

et al. 2021

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Low-volume manufacturing remains a challenge, especially for parts that need to be injection-molded. Freeform injection molding (FIM) is a novel method that combines elements from direct additive manufacturing (DAM) and injection molding (IM) to resolve some of the challenges seen in low-volume injection molding. In this study, we use a design science approach to explore the suitability of FIM for the manufacturing of low volume injection-molded parts. We provide an overview of the benefits and limitations of traditional IM and discuss how DAM and indirect additive manufacturing (IAM) methods, such as soft tooling and FIM, can address some of the existing drawbacks of IM for short series production. A set of different parts was identified and assessed using a design science-based approach to demonstrate how to incubate FIM as a solution to address the challenges faced in short series production with IM. This initial process innovation was followed by solution refinement, involving the optimization of the FIM processes. Finally, a “cross-case” analysis was conducted using the framework of context, intervention, mechanism and outcomes to generate insights about the generalizability of the results. It is concluded that FIM combines the short lead-times, low start-up costs and design freedom of DAM with the versatility and scalability of IM to allow manufacturers to bring low volume products to the market faster, more cheaply and with lower risk, and to maintain the relevance of these products through easy customization and adaptations once they have been launched.

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“…Process optimization approaches are applied to assess the impact of above-mentioned factors on the attainability of desired objectives such as functionality, aesthetics, and efficiency [16,42]. Several studies have highlighted the benefits of using simulation driven DfAM to achieve desired requirements and function [6][7][8]18,42,[52][53][54][55]. The scan strategy refers to the type of scan pattern, the number of scan count, and the orientation of scanning paths in respect to each other in specific areas within the single layer.…”

Section: Simulation Driven Dfam In L-pbfmentioning

confidence: 99%

Integration of Simulation Driven DfAM and LCC Analysis for Decision Making in L-PBF

Nyamekye

Unt

Salminen

et al. 2020

Metals

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Laser based powder bed fusion (L-PBF) is used to manufacture parts layer by layer with the energy of laser beam. The use of L-PBF for building functional parts originates from the design freedom, flexibility, customizability, and energy efficiency of products applied in dynamic application fields such as aerospace and automotive. There are challenges and drawbacks that need to be defined and overcome before its adaptation next to rivaling traditional manufacturing methods. Factors such as high cost of L-PBF machines, metal powder, post-preprocessing, and low productivity may deter its acceptance as a mainstream manufacturing technique. Understanding the key cost drivers of L-PBF that influence productivity throughout the whole lifespan of products will facilitate the decision-making process. Functional and operational decisions can yield profitability and increase competitiveness among advanced manufacturing sectors. Identifying the relationships between the phases of the life cycle of products influences cost-effectiveness. The aim of the study is to investigate the life cycle cost (LCC) and the impact of design to it in additive manufacturing (AM) with L-PBF. The article provides a review of simulation driven design for additive manufacturing (simulation driven DfAM) and LCC for metallic L-PBF processes and examines the state of the art to outline the merits, demerits, design rules, and life cycle models of L-PBF. Practical case studies of L-PBF are discussed and analysis of the interrelating factors of the different life phases are presented. This study shows that simulation driven DfAM in the design phase increases the productivity throughout the whole production and life span of L-PBF parts. The LCC model covers the whole holistic lifecycle engineering of products and offers guidelines for decision making.

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A Design Framework for Additive Manufacturing: Integration of Additive Manufacturing Capabilities in the Early Design Process

Cited by 71 publications

References 55 publications

Directed Energy Deposition (DED) Process: State of the Art

Directed Energy Deposition (DED) Process: State of the Art

Assessing the Suitability of Freeform Injection Molding for Low Volume Injection Molded Parts: A Design Science Approach

Integration of Simulation Driven DfAM and LCC Analysis for Decision Making in L-PBF

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