What are the two common methods to overcome some of the bulk geometric limitations of legacy CAD systems?

Two common methods to overcome some of the bulk geometric limitations of legacy CAD systems are haptic modelling and reverse engineering.

What is the way to maximize the business benefits of AM?

maximizing the business benefits of AM requires a through-life approach that considers production, use, maintenance, repair, and disposal.

What are the challenges of creating freeform external geometries?

The organic, freeform external geometries that can be created by AM require more complex measurement techniques and greater data processing capabilities.

How many different FDM samples were able to estimate the build time?

After 72 training cases, they were able to estimate the build time of six different FDM samples with errors ranging from 6.07 to 20.3%.

What are the main features of the design rules for laser sintering?

In the academic literature, Adam and Zimmer [10] presented a catalogue of design rules for laser sintering, laser melting, and FDM that address geometric constraints such as sharp edges, element transitions, unsupported features, and feature spacing.

What is the common strategy for maximizing the strength of a part?

Designers typically compensate for these mechanical effects by orienting the part to maximize its strength during the build, by adding support structures to the part, or by designing the part to be self-supporting throughout the printing process.

How many pieces of plastic was economical for the smaller part?

It was estimated that LS was economical up to 14,000 pieces for the smaller part (Fig. 50) and up to 700 pieces for the larger part.

How much did they estimate the cost of a single DMLS assembly?

They estimated the cost of a single DMLS assembly to be 526.31 EUR (material cost 5%, pre-processing cost 1%, build costs 90%, post processing cost 4%) vs. 21.29 + 21,000/N EUR for HDPC.

What was the cost of a part produced by LS and injection molding?

It indicated that the cost per AM part was driven by the production speed and the break-even point between LS and injection molding was driven by part size.

What are the main challenges when designing for heterogeneity?

there remain many challenges when designing for heterogeneity taking into account the shape and material distribution in order to meet the functionality, requirements or constraints of the artifact.

How many input variables were used to obtain a good estimate of build time?

This approach requires very few input variables to obtain a good estimate of build time (generally conservative and within 12% of the actual build time), however only one type of machine was used and the settings were kept constant.

How much do cost models assume for AM products?

Most cost models assume higher production volumes for a single design and therefore underestimate the labor costs of AM products.

What are the options for converting solid models of truss structures?

Past solutions have involved complete solid models of truss structures using geometric modeling kernels such as ACIS [347], algorithms [24][88][140], and unit cell libraries [16][70][246] (Fig. 37).

What was the main reason for the rapid prototyping and model making of AM?

the high cost, limited material choices, and low dimensional accuracy of these machines limited their industrial application to rapid prototyping and model making.

Open AccessJournal Article10.1016/J.CIRP.2016.05.004

Design for additive manufacturing: trends, opportunities, considerations, and constraints

Mary Kathryn Thompson, +10 more

- 01 Jan 2016

- Cirp Annals-manufacturing Technology

- Vol. 65, Iss: 2, pp 737-760

1.6K

TL;DR: In the case of aircraft components, AM technology enables low-volume manufacturing, easy integration of design changes and, at least as importantly, piece part reductions to greatly simplify product assembly.

Abstract: The past few decades have seen substantial growth in Additive Manufacturing (AM) technologies. However, this growth has mainly been process-driven. The evolution of engineering design to take advantage of the possibilities afforded by AM and to manage the constraints associated with the technology has lagged behind. This paper presents the major opportunities, constraints, and economic considerations for Design for Additive Manufacturing. It explores issues related to design and redesign for direct and indirect AM production. It also highlights key industrial applications, outlines future challenges, and identifies promising directions for research and the exploitation of AM's full potential in industry.

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Most frequently asked questions

1. What are the contributions mentioned in the paper "Design for additive manufacturing: trends, opportunities, considerations and constraints" ?

In this paper, the main design opportunities, considerations and constraints related to AM technologies, including production time and cost, are discussed.

2. What have the authors stated for future works in "Design for additive manufacturing: trends, opportunities, considerations and constraints" ?

This section explores some of the future challenges and coming trends that will shape DfAM and the technology it will enable.

3. What are the three categories of build time models?

Existing build time models can be grouped into 3 categories: models dedicated to one process using a limit set of parameters; generic build time models that use many parameters to estimate build times; and parametric models that use neural networks to predict production times based on historic data.

4. Why is AM being used to create custom objects?

Because AM simultaneously creates an object’s material and geometry, it can be used to create custom alloys and composite materials.

Fig. 16. Brackets before and after topology optimization: Airbus A320 nacelle hinge brackets as-designed for cast steel and optimized for titanium (left) and Airbus A380 brackets as designed and optimized for stainless steel (right) [105]. The optimized brackets were produced by direct metal laser sintering (DMLS).

Fig. 19. Customized laser sintered foot orthoses from Materialise’s AFootprint project (left) and customized selective laser sintered wrist splint produced by Fraunhofer IPA. Images via [251].

Fig. 17. Types of customization. Redrawn from [59].

Fig. 14. Thermal conditioning ring with milled cooling channels enclosed by a welded cover (left) and with additively manufactured conformal cooling channels (right). Courtesy of ASML.

Fig. 18. Titanium implants for the skull (left, [103]) and pelvis (right, [107]) produced using and EOSINT M 280.

Fig. 15. Temperature plots from finite element models of the milled conditioning ring (left) and the additively manufactured conditioning ring (right). Shown with the same temperature scale. Courtesy of ASML.

Citations

•Journal Article•10.1088/1757-899X/580/1/012006

Additive manufacturing of metal components ─ process-material interaction in different process chains

Hans Nørgaard Hansen, +8 more

- 01 Aug 2019

TL;DR: In this paper, the authors describe metal additive manufacturing (AM) processes in general, and laser bed fusion processes in particular, and the process characteristics are described, and various modelling approaches demonstrated.

...read moreread less

Book Chapter•10.1007/978-3-030-29041-2_2

Expectations of Additive Manufacturing for the Decade 2020–2030

Henrique A. Almeida, +1 more

- 02 Oct 2019

TL;DR: In this paper, the authors present the AM prospects for the next decade and its prospective impact on business and industrial production models, including the freeform building capacity plays a relevant role on industrial applications where conventional manufacturing approaches are not technically or even not economically feasible.

...read moreread less

10.2139/ssrn.4137486

Scheduling of Build and Post Processes for Decomposed Parts in Additive Manufacturing

Yosep Oh, +1 more

- 01 Sep 2022

- Social Science Research Network

•Journal Article•10.3390/jcs7030112

A Systematic Approach to Determine the Cutting Parameters of AM Green Zirconia in Finish Milling

Laurent Spitaels, +4 more

- 10 Mar 2023

- Journal of composites science

TL;DR: In this article , a systematic approach to experimentally determine the cutting parameters of green AM zirconia parts was proposed, and three tools, one dedicated to thermoplastics, one to composites, and a universal tool, were tested.

...read moreread less

•Journal Article•10.1016/J.PROCIR.2021.05.124

A practical redesign method for functional additive manufacturing

Weijun Wang, +3 more

- 01 Jan 2021

- Procedia CIRP

TL;DR: In this paper, the authors propose a method combining both subtractive and generative methods to define material distribution in the design space with consideration of AM manufacturability analysis and functional requirements.

...read moreread less

...

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References

Journal Article•10.1016/S0142-9612(00)00121-6

Scaffolds in tissue engineering bone and cartilage.

Dietmar W. Hutmacher

- 15 Dec 2000

- Biomaterials

TL;DR: Research on the tissue engineering of bone and cartilage from the polymeric scaffold point of view is reviews from a biodegradable and bioresorbable perspective.

...read moreread less

5.3K

Journal Article•10.1126/SCIENCE.1096796

Metamaterials and negative refractive index.

David R. Smith, +2 more

- 06 Aug 2004

- Science

TL;DR: Recent advances in metamaterials research are described and the potential that these materials may hold for realizing new and seemingly exotic electromagnetic phenomena is discussed.

...read moreread less

4.6K

•Book

Additive Manufacturing Technologies: Rapid Prototyping to Direct Digital Manufacturing

Ian Gibson, +2 more

- 01 Jan 2009

TL;DR: Gibson et al. as discussed by the authors presented a comprehensive overview of additive manufacturing technologies plus descriptions of support technologies like software systems and post-processing approaches, and provided systematic solutions for process selection and design for AM Additive Manufacturing Technologies: Rapid Prototyping to Direct Digital Manufacturing.

...read moreread less

4.4K

•Book

Product design for manufacture and assembly

Geoffrey Boothroyd

- 01 Jan 1983

TL;DR: The importance of taking careful account of manufacturing and assembly problems in the early stages of product design is stressed and the philosophy of the Design for Manufacture and Assembly (DFMA) methodology and its application are explained.

...read moreread less

•Journal Article•10.1126/SCIENCE.1252291

Ultralight, ultrastiff mechanical metamaterials

Xiaoyu Zheng, +12 more

- 20 Jun 2014

- Science

TL;DR: A class of microarchitected materials that maintain a nearly constant stiffness per unit mass density, even at ultralow density is reported, which derives from a network of nearly isotropic microscale unit cells with high structural connectivity and nanoscale features, whose structural members are designed to carry loads in tension or compression.

...read moreread less

1.9K

...

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Design for additive manufacturing: trends, opportunities, considerations, and constraints

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AI Agents for this Paper

Most frequently asked questions

1. What are the contributions mentioned in the paper "Design for additive manufacturing: trends, opportunities, considerations and constraints" ?

2. What have the authors stated for future works in "Design for additive manufacturing: trends, opportunities, considerations and constraints" ?

3. What are the three categories of build time models?

4. Why is AM being used to create custom objects?

5. What are the two common methods to overcome some of the bulk geometric limitations of legacy CAD systems?

6. What is the way to maximize the business benefits of AM?

7. What are the challenges of creating freeform external geometries?

8. How many different FDM samples were able to estimate the build time?

9. What are the main features of the design rules for laser sintering?

10. What is the common strategy for maximizing the strength of a part?

11. How many pieces of plastic was economical for the smaller part?

12. How much did they estimate the cost of a single DMLS assembly?

13. What was the cost of a part produced by LS and injection molding?

14. What are the main challenges when designing for heterogeneity?

15. How many input variables were used to obtain a good estimate of build time?

16. How much do cost models assume for AM products?

17. What are the options for converting solid models of truss structures?

18. What was the main reason for the rapid prototyping and model making of AM?

Figures

Citations

Additive manufacturing of metal components ─ process-material interaction in different process chains

Expectations of Additive Manufacturing for the Decade 2020–2030

Scheduling of Build and Post Processes for Decomposed Parts in Additive Manufacturing

A Systematic Approach to Determine the Cutting Parameters of AM Green Zirconia in Finish Milling

A practical redesign method for functional additive manufacturing

References

Scaffolds in tissue engineering bone and cartilage.

Metamaterials and negative refractive index.

Additive Manufacturing Technologies: Rapid Prototyping to Direct Digital Manufacturing

Product design for manufacture and assembly

Ultralight, ultrastiff mechanical metamaterials

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