Hostname: page-component-586b7cd67f-l7hp2 Total loading time: 0 Render date: 2024-11-22T21:18:35.377Z Has data issue: false hasContentIssue false
  • English
  • Français

A STRUCTURED APPROACH TO REDUCE DESIGN ITERATIONS IN ADDITIVE MANUFACTURING

Published online by Cambridge University Press:  27 July 2021

Laura Wirths ,
Matthias Bleckmann  and
Kristin Paetzold
Laura Wirths*
Affiliation:
Bundeswehr University Munich
Matthias Bleckmann
Affiliation:
Bundeswehr Research Institute for Materials, Fuels and Lubricants (WIWeB)
Kristin Paetzold
Affiliation:
Bundeswehr University Munich
*
Wirths, Laura, Bundeswehr University Munich, Department of Aerospace Engineering, Germany, [email protected]

Abstract

Core share and HTML view are not available for this content. However, as you have access to this content, a full PDF is available via the ‘Save PDF’ action button.

Additive Manufacturing technologies are based on a layer-by-layer build-up. This offers the possibility to design complex geometries or to integrate functionalities in the part. Nevertheless, limitations given by the manufacturing process apply to the geometric design freedom. These limitations are often unknown due to a lack of knowledge of the cause-effect relationships of the process. Currently, this leads to many iterations until the final part fulfils its functionality. Particularly for small batch sizes, producing the part at the first attempt is very important. In this study, a structured approach to reduce the design iterations is presented. Therefore, the cause-effect relationships are systematically established and analysed in detail. Based on this knowledge, design guidelines can be derived. These guidelines consider process limitations and help to reduce the iterations for the final part production. In order to illustrate the approach, the spare parts production via laser powder bed fusion is used as an example.

Keywords

3D printingAdditive ManufacturingDesign for Additive Manufacturing (DfAM)Process modellingDesign engineering
Type
Article
Information
Proceedings of the Design Society , Volume 1: ICED21 , August 2021 , pp. 231 - 240
Creative Commons
Creative Common License - CCCreative Common License - BYCreative Common License - NCCreative Common License - ND
This is an Open Access article, distributed under the terms of the Creative Commons Attribution-NonCommercial-NoDerivatives licence (http://creativecommons.org/licenses/by-nc-nd/4.0/), which permits non-commercial re-use, distribution, and reproduction in any medium, provided the original work is unaltered and is properly cited. The written permission of Cambridge University Press must be obtained for commercial re-use or in order to create a derivative work.
Copyright
The Author(s), 2021. Published by Cambridge University Press

References

Beiderbeck, D., Krüger, H. and Minshall, T. (2020), “The Future of Additive Manufacturing in Sports”, in Schmidt, S.L. (Ed.), 21st Century Sports, Future of Business and Finance, Springer International Publishing, Cham, pp. 111–132.10.1007/978-3-030-50801-2_7CrossRefGoogle Scholar
Di Wang, Yang, Yi, Y., and Su, Z., X. (2013), “Research on the fabricating quality optimization of the overhanging surface in SLM process”, The International Journal of Advanced Manufacturing Technology, Vol. 65 No. 9-12, pp. 1471–1484. 10.1007/s00170-012-4271-4.10.1007/s00170-012-4271-4CrossRefGoogle Scholar
Diegel, O., Nordin, A. and Motte, D. (2019), A Practical Guide to Design for Additive Manufacturing, Springer Singapore, Singapore. 10.1007/978-981-13-8281-9.CrossRefGoogle Scholar
Du Plessis, A. and Macdonald, E. (2020), “Hot isostatic pressing in metal additive manufacturing: X-ray tomography reveals details of pore closure”, Additive Manufacturing, Vol. 34, p. 101191. 10.1016/j.addma.2020.101191.CrossRefGoogle Scholar
Frandsen, C.S., Nielsen, M.M., Chaudhuri, A., Jayaram, J. and Govindan, K. (2020), “In search for classification and selection of spare parts suitable for additive manufacturing: a literature review”, International Journal of Production Research, Vol. 58 No. 4, pp. 970–996. 10.1080/00207543.2019.1605226.CrossRefGoogle Scholar
Fraunhofer IAPT (2020), And suddenly the printed wheel carrier brakes…, available at: https://www.iapt.fraunhofer.de/en/press-media/Press_releases/Press_Release_Fiat_Chrysler.html.Google Scholar
Jakoby, W. (2019), Qualitätsmanagement für Ingenieure, Springer Fachmedien Wiesbaden, Wiesbaden. 10.1007/978-3-658-26596-0.10.1007/978-3-658-26596-0CrossRefGoogle Scholar
Kasperovich, G. and Hausmann, J. (2015), “Improvement of fatigue resistance and ductility of TiAl6V4 processed by selective laser melting”, Journal of Materials Processing Technology, Vol. 220, pp. 202–214. 10.1016/j.jmatprotec.2015.01.025.10.1016/j.jmatprotec.2015.01.025CrossRefGoogle Scholar
Kranz, J., Herzog, D. and Emmelmann, C. (2015), “Design guidelines for laser additive manufacturing of lightweight structures in TiAl6V4”, Journal of Laser Applications, Vol. 27 No. S1, S14001. 10.2351/1.4885235.CrossRefGoogle Scholar
Li, B.-Q., Li, Z., Bai, P., Liu, B. and Kuai, Z. (2018), “Research on Surface Roughness of AlSi10Mg Parts Fabricated by Laser Powder Bed Fusion”, Metals, Vol. 8 No. 7, p. 524. 10.3390/met8070524.CrossRefGoogle Scholar
Lindemann, U., Maurer, M. and Braun, T. (2009), “Modeling the Multiple-Domain Matrix”, in Lindemann, U., Maurer, M. and Braun, T. (Eds.), Structural complexity management: An approach for the field of product design, Springer-Verlag Berlin Heidelberg, Berlin, Heidelberg, pp. 67–78.10.1007/978-3-540-87889-6_5CrossRefGoogle Scholar
Maamoun, A.H., Xue, Y.F., Elbestawi, M.A. and Veldhuis, S.C. (2018), “Effect of Selective Laser Melting Process Parameters on the Quality of Al Alloy Parts: Powder Characterization, Density, Surface Roughness, and Dimensional Accuracy”, Materials (Basel, Switzerland), Vol. 11 No. 12. 10.3390/ma11122343.Google Scholar
Mertens, R., Clijsters, S., Kempen, K. and Kruth, J.-P. (2014), “Optimization of Scan Strategies in Selective Laser Melting of Aluminum Parts With Downfacing Areas”, Journal of Manufacturing Science and Engineering, Vol. 136 No. 6. 10.1115/1.4028620.10.1115/1.4028620CrossRefGoogle Scholar
Montero, J., Weber, S., Bleckmann, M. and Paetzold, K. (2020), “A methodology for the decentralised design and production of additive manufactured spare parts”, Production & Manufacturing Research, Vol. 8 No. 1, pp. 313–334. 10.1080/21693277.2020.1790437.10.1080/21693277.2020.1790437CrossRefGoogle Scholar
Schlauf, T., Lutter-Günther, M. and Rosenkranz, C. (2019), Project report – AM 4 Industry - LBM Additive Manufacturing Defect Catalogue.Google Scholar
Shinde, M.S. and Ashtankar, K.M. (2017), “Additive manufacturing–assisted conformal cooling channels in mold manufacturing processes”, Advances in Mechanical Engineering, Vol. 9 No. 5, 168781401769976. 10.1177/1687814017699764.CrossRefGoogle Scholar
Stef, J., Poulon-Quintin, A., Redjaimia, A., Ghanbaja, J., Ferry, O., Sousa, M. de and Gouné, M. (2018), “Mechanism of porosity formation and influence on mechanical properties in selective laser melting of Ti-6Al-4V parts”, Materials & Design, Vol. 156, pp. 480–493. 10.1016/j.matdes.2018.06.049.10.1016/j.matdes.2018.06.049CrossRefGoogle Scholar
Thomas, D.J. (2009), “The Development of Design Rules for Selective Laser Melting”, Thesis, University of Wales Institute, Cardiff, 2009.Google Scholar
Weber, S., Montero, J., Bleckmann, M. and Paetzold, K. (2020a), “Parameters on support structure design for metal additive manufacturing”, Proceedings of the Design Society: DESIGN Conference, Vol. 1, pp. 1145–1154. 10.1017/dsd.2020.14.CrossRefGoogle Scholar
Weber, S., Montero, J., Petroll, C., Schäfer, T., Bleckmann, M. and Paetzold, K. (2020b), “The Fracture Behavior and Mechanical Properties of a Support Structure for Additive Manufacturing of Ti-6Al-4V”, Crystals, Vol. 10 No. 5, p. 343. 10.3390/cryst10050343.10.3390/cryst10050343CrossRefGoogle Scholar
Zaeh, M.F. and Branner, G. (2010), “Investigations on residual stresses and deformations in selective laser melting”, Production Engineering, Vol. 4 No. 1, pp. 35–45. 10.1007/s11740-009-0192-y.CrossRefGoogle Scholar