Challenges of additive manufacturing technologies from an optimisation perspective

Abstract

-Three-dimensional printing offers varied possibilities of design that can be bridged to optimisation tools. In this review paper, a critical opinion on optimal design is delivered to show limits, benefits and ways of improvement in additive manufacturing. This review emphasises on design constrains related to additive manufacturing and differences that may appear between virtual and real design. These differences are explored based on 3D imaging techniques that are intended to show defect related processing. Guidelines of safe use of the term ''optimal design'' are derived based on 3D structural information.

The manufacture of honeycomb cores using Fused Deposition Modeling

“…Many methods for improving the mechanical properties of the components have been suggested, such as the use of curved layers, 30,31 design optimization, 32,33 and process parameter optimization. 18,19,34,35 Material choice is limited by the melting point achievable by the extruder and viscosity during extrusion.…”

Microstructure, Thermal and Mechanical Behavior of 3D Printed Acrylonitrile Styrene Acrylate

“…Despite the simple implementation of an FDM process, it has some flaws that are more or less related to the material discontinuity created by the laying down process. Indeed, because the filament is only extruded continuously in one direction, the building of 3D structures generates two main discontinuities that are represented by the discontinuous contours of the path filaments . Problems related to the mechanical performance can be faced especially with the dependence of the measured properties on the orientation of the workpiece during the printing and the large amount of interfaces that are created by the inter‐filament necking.…”

“…Indeed, because the filament is only extruded continuously in one direction, the building of 3D structures generates two main discontinuities that are represented by the discontinuous contours of the path filaments. [4,5] Problems related to the mechanical performance can be faced especially with the dependence of the measured properties on the orientation of the workpiece during the printing [5,6] and the large amount of interfaces that are created by the inter-filament necking. All these problems lead to a mechanical anisotropy and a loss of performance that are well documented in the literature.…”

Full-Density Fused Deposition Modeling Dimensional Error as a Function of Raster Angle and Build Orientation: Large Dataset for Eleven Materials

“…However, there are some limitations and problems that need to be considered and addressed when using AM, dimensional accuracy [13,14], process and geometric repeatability [15][16][17], and material defects [18][19][20] being the primary considerations. While all of these are important to examine, the most important from the perspective of engineering design are the dimensional accuracy and repeatability of the final parts.…”