An optimisation framework for designs for additive manufacturing combining design, manufacturing and post-processing

Abstract

Purpose The purpose of this paper is to present a Design for Additive Manufacturing (DfAM) methodology that connects several methods, from geometrical design to post-process selection, into a common optimisation framework. Design/methodology/approach A design methodology is formulated and tested in a case study. The outcome of the case study is analysed by comparing the obtained results with alternative designs achieved by using other design methods. The design process in the case study and the potential of the method to be used in different settings are also discussed. Finally, the work is concluded by stating the main contribution of the paper and highlighting where further research is needed. Findings The proposed method is implemented in a novel framework which is applied to a physical component in the case study. The component is a structural aircraft part that was designed to minimise weight while respecting several static and fatigue structural load cases. An addition goal is to minimise the manufacturing cost. Designs optimised for manufacturing by two different AM machines (EOS M400 and Arcam Q20+), with and without post-processing (centrifugal finishing) are considered. The designs achieved in this study show a significant reduction in both weight and cost compared to one AM manufactured geometry designed using more conventional methods and one design milled in aluminium. Originality/value The method in this paper allows for the holistic design and optimisation of components while considering manufacturability, cost and component functionality. Within the same framework, designs optimised for different setups of AM machines and post-processing can be automatically evaluated without any additional manual work.

Enhancing design automation for components of electric machines: a systematic approach

“…The parts architecture is derived from an abstract system model and serves to define the different design elements and their functional and geometrical interactions. A similar approach including a more detailed description of tasks for the different steps is presented by Wiberg et al (2023).…”

Design Automation Systems for the Product Development Process: Reflections from Five Industrial Case Studies

“…Output is design with a trade-off between cost and being lightweight, as well as manufacturing instructions for selected designs. This DA system is further described by Wiberg et al (2021).…”

Review on study of design optimization for additive manufacturing of various mechanical/machine components

“…The results demonstrate a decrease in volume of 37% and maximum displacement of 8%, respectively. [11].The structural aircraft component was designed to be as light as feasible while satisfying the criteria of a variety of static and fatigue structural load conditions. Another aim was to maintain production costs as low as feasible.…”