(Re)Design for Additive Manufacturing

Hällgren, Sebastian; Pejryd, Lars; Ekengren, Jens

doi:10.1016/j.procir.2016.04.150

Cited by 78 publications

(39 citation statements)

References 9 publications

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“…The purpose of the following paragraphs is to give an overview of existing methodologies before a compilation of the existing methodologies in the form of a detailed method covering the whole design process is presented in Figure 6. Hällgren et al (2016) do not present a design process but discuss how TO could be combined with experience and design rules during the design process. Ponche et al (2014) propose a three-step methodology which starts with identifying build orientation, followed by a TO, and ending with optimization of manufacturing settings.…”

Section: State Of the Art And Classificationmentioning

confidence: 99%

Design for additive manufacturing – a review of available design methods and software

Wiberg

Persson

Ölvander

2019

RPJ

144

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Purpose This paper aims to review recent research in design for additive manufacturing (DfAM), including additive manufacturing (AM) terminology, trends, methods, classification of DfAM methods and software. The focus is on the design engineer’s role in the DfAM process and includes which design methods and tools exist to aid the design process. This includes methods, guidelines and software to achieve design optimization and in further steps to increase the level of design automation for metal AM techniques. The research has a special interest in structural optimization and the coupling between topology optimization and AM. Design/methodology/approach The method used in the review consists of six rounds in which literature was sequentially collected, sorted and removed. Full presentation of the method used could be found in the paper. Findings Existing DfAM research has been divided into three main groups – component, part and process design – and based on the review of existing DfAM methods, a proposal for a DfAM process has been compiled. Design support suitable for use by design engineers is linked to each step in the compiled DfAM process. Finally, the review suggests a possible new DfAM process that allows a higher degree of design automation than today’s process. Furthermore, research areas that need to be further developed to achieve this framework are pointed out. Originality/value The review maps existing research in design for additive manufacturing and compiles a proposed design method. For each step in the proposed method, existing methods and software are coupled. This type of overall methodology with connecting methods and software did not exist before. The work also contributes with a discussion regarding future design process and automation.

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Section: State Of the Art And Classificationmentioning

confidence: 99%

Design for additive manufacturing – a review of available design methods and software

Wiberg

Persson

Ölvander

2019

RPJ

144

View full text Add to dashboard Cite

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“…The reason behind the high number of papers underlining metal as the focus is due to their vast industrial application, the high cost of new metal parts as well as the inefficiency and cost involved in manual reparation [28,81].…”

Section: Product or Object Materialsmentioning

confidence: 99%

Additive Manufacturing for Repair and Restoration in Remanufacturing: An Overview from Object Design and Systems Perspectives

2019

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Repair and restoration is an important step in remanufacturing as it ensures end-of-life products are returned to as-new condition before entering the subsequent life cycle. Currently, such processes are carried out manually by skilled workers. The advent of additive manufacturing (AM) has encouraged researchers to investigate its potential in automated repair and restoration, thus rendering it as a more effective method for remanufacturing. However, the application of this widespread technology for repair and restoration in remanufacturing is still new. This paper provides an overview of the principles and capabilities offered by the existing metal AM technology for object repair and restoration namely, direct energy deposition, powder bed fusion, and cold spray technology. Their applications in the repair and restoration of remanufacturable components are presented and discussed along with issues requiring attention from the perspectives of object design and process systems capabilities. The study provides a compilation of the challenges in AM repair and restoration, which primarily lie in the aspects of geometrical complexity, geometric dimensioning and tolerancing, material compatibility, and pre-processing requirements since it is critical for remanufacturing to restore end-of-life components to as new-condition. The paper concludes with suggestions for further works in AM restoration to enable product life cycle extension in the circular economy.

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“…Secondly, design modifications aimed at reaching functional enhancements of the component potentially lead to improved inherent performance values of the components. Thirdly, approaches such as part consolidation attempt to rethink products by combining several parts into one, omitting the assembly stage for merged parts [44]- [46]; even the redesign and manufacture of several assemblies as one seem plausible.…”

Section: Design Aspectsmentioning

confidence: 99%

“…DfAM defines an engineering design process following design requirements, rules and guidelines regarding the underlying process and material-dependent restrictions and opportunities in AM; this allows taking full advantage of inherent capabilities and ensuring manufacturability [46]. This design process results in new designs, typically designs with higher degrees of shape complexity, aiming to be either functionally advantageous, economically more feasible, or both [44]. Common examples of applied (re)design processes are described by both topology optimization of existing components to create enhanced lightweight designs and part-consolidation approaches to combine single parts into one by maintaining their functionality; these (re)design processes save both manufacturing and assembly costs [47], [48].…”

Section: Design Aspectsmentioning

confidence: 99%

Axiomatic Design to Foster Additive Manufacturing-Specific Design Knowledge

Chekurov

Kretzschmar

Rossoni

et al. 2019

Volume 14: Design, Systems, and Complexity

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Axiomatic design has the potential to help designers understand the increased design freedom and limitations of additive manufacturing prior to starting the actual design process. The purpose of this study is to verify the usefulness of Axiomatic Design in the design process of complex additively manufactured components. The article uses a case study involving the design of a non-assembly turbine to demonstrate that Axiomatic Design can be applied as a supportive tool to acquire information on new limitations imposed by additive manufacturing, such as minimum wall thickness and maximum size of parts. The use of axiomatic design is demonstrated by describing the process of decomposition of the non-assembly turbine and examining the suitability of the general design according to the independence axiom. The resulting decomposition chart is subsequently used as a basis by the authors to design individually two competing designs of a turbine. Finally, the information axiom is used to determine the design with the lowest information content according to design (part and support volume), performance (pressure drop) and economic parameters (cost).

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(Re)Design for Additive Manufacturing

Cited by 78 publications

References 9 publications

Design for additive manufacturing – a review of available design methods and software

Design for additive manufacturing – a review of available design methods and software

Additive Manufacturing for Repair and Restoration in Remanufacturing: An Overview from Object Design and Systems Perspectives

Axiomatic Design to Foster Additive Manufacturing-Specific Design Knowledge

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