Design for Additive Manufacturing: Methods and Tools

Mandolini, Marco; Pradel, Patrick; Cicconi, Paolo

doi:10.3390/app12136548

Cited by 8 publications

(6 citation statements)

References 23 publications

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“…where E is the Young's modulus of the material and I is the second moment of area. Solving (21) for P gives:…”

Section: Load-bearing Capacities At the Same Maximum Permissible Defl...mentioning

confidence: 99%

“…Although the load per beam increases in the aggregated structure, this is outweighed by the increase in the second moment of area of the cross section. For cantilevered beams, the deformation is given by Equation (21). Despite the increase of the load P in the numerator from aggregating the loads, this increase is outweighed by the more significant increase of the second moment of area 'I' of the cross sections, caused by the increased radius r. Indeed, the second moment of area depends on the fourth power of the radius of the beam (I = πr 4 /4).…”

Section: Load-bearing Capacities At the Same Maximum Permissible Defl...mentioning

confidence: 99%

“…A major trend in lightweight parts obtained through design is the simulationdriven design technique known as 'topology optimization' [18,19]. In addition, lightweight components can also be obtained using advanced manufacturing technologies such as advanced metal forming [20] and additive manufacturing [21,22].…”

Section: Introductionmentioning

confidence: 99%

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Lightweight Designs and Improving the Load-Bearing Capacity of Structures by the Method of Aggregation

Todinov

2024

Mathematics

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The paper introduces a powerful method for developing lightweight designs and enhancing the load-bearing capacity of common structures. The method, referred to as the ‘method of aggregation’, has been derived from reverse engineering of sub-additive and super-additive algebraic inequalities. The essence of the proposed method is consolidating multiple elements loaded in bending into a reduced number of elements with larger cross sections but a smaller total volume of material. This procedure yields a huge reduction in material usage and is the first major contribution of the paper. For instance, when aggregating eight load-carrying beams into two beams supporting the same total load, the material reduction was more than 1.58 times. The second major contribution of the paper is in demonstrating that consolidating multiple elements loaded in bending into a reduced number of elements with larger cross sections but the same total volume of material leads to a big increase in the load-bearing capacity of the structure. For instance, when aggregating eight cantilevered or simply supported beams into two beams with the same volume of material, the load-bearing capacity until a specified tensile stress increased twice. At the same time, the load-bearing capacity until a specified deflection increased four times.

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“…where E is the Young's modulus of the material and I is the second moment of area. Solving (21) for P gives:…”

Section: Load-bearing Capacities At the Same Maximum Permissible Defl...mentioning

confidence: 99%

Section: Load-bearing Capacities At the Same Maximum Permissible Defl...mentioning

confidence: 99%

See 1 more Smart Citation

Lightweight Designs and Improving the Load-Bearing Capacity of Structures by the Method of Aggregation

Todinov

2024

Mathematics

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“…Considering the summary of some research works discussed above out of the myriads of works that can be found in the literature, DfAM enables us to use a set of design methods and strategies by which we can optimise the functional performance, manufacturability, reliability and the final cost subjected to the unique capabilities of AM technologies. Further methods and tools that have been used for DfAM were thoroughly investigated in [283].…”

Section: Design Guides For Am Processes and Parts With Special Featuresmentioning

confidence: 99%

A Survey on Process Modelling, Innovation, Design, and Material Characterisation in Additive Manufacturing

Hassani

Emami

Tjahjowidodo

et al. 2023

Digital Manufacturing Technology

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The unique design freedom offered by additive manufacturing (AM) technologies enables engineers to develop more innovative products with relatively lower costs within a shorter period of processing time in comparison with conventional manufacturing methods. On the other hand, the unique capabilities of AM have created a platform for researchers to combine several engineering methods with the new manufacturing technique to grow industrial applications as well as resolve the existing issues with AM processes. Understanding the research values that AM offers academic environments, this paper performs a systematic survey on AM-related research topics in the fields of mechanical engineering and materials science that have attracted much attention from research teams over the last few years. These topics, namely process modelling in AM, innovative research in AM, generative design by AM, material characterisation in AM processes, and finally, design for additive manufacturing (DfAM), are notably investigated through this study.

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“…In contrast to conventional manufacturing approaches, AM techniques offer enormous potential for producing components with intricate geometries [31,32]. This astonishing flexibility makes AM a favorable technology for generative design in the development of customized, multi-scale, and multi-material high-performance structures [33]. While the manufacturability of unusual, complicated structures is no longer a critical concern when employing AM, the development of new opportunities calls for more refined and efficient design approaches.…”

Section: Introductionmentioning

confidence: 99%

Non-Conventional Wing Structure Design with Lattice Infilled through Design for Additive Manufacturing

Khan,

Acanfora,

Riccio

2024

Materials

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Lightweight structures with a high stiffness-to-weight ratio always play a significant role in weight reduction in the aerospace sector. The exploration of non-conventional structures for aerospace applications has been a point of interest over the past few decades. The adaptation of lattice structure and additive manufacturing in the design can lead to improvement in mechanical properties and significant weight reduction. The practicality of the non-conventional wing structure with lattices infilled as a replacement for the conventional spar–ribs wing is determined through finite element analysis. The optimal lattice-infilled wing structures are obtained via an automated iterative method using the commercial implicit modeling tool nTop and an ANSYS workbench. Among five different types of optimized lattice-infilled structures, the Kelvin lattice structure is considered the best choice for current applications, with comparatively minimal wing-tip deflection, weight, and stress. Furthermore, the stress distribution dependency on the lattice-unit cell type and arrangement is also established. Conclusively, the lattice-infilled structures have shown an alternative innovative design approach for lightweight wing structures.

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Design for Additive Manufacturing: Methods and Tools

Abstract: Additive Manufacturing (AM), one of the nine enabling technologies of Industry 4.0, is experiencing rapid growth [...]

Cited by 8 publications

References 23 publications

Lightweight Designs and Improving the Load-Bearing Capacity of Structures by the Method of Aggregation

Lightweight Designs and Improving the Load-Bearing Capacity of Structures by the Method of Aggregation

A Survey on Process Modelling, Innovation, Design, and Material Characterisation in Additive Manufacturing

Non-Conventional Wing Structure Design with Lattice Infilled through Design for Additive Manufacturing

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