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(Re)Design for Additive Manufacturing
Örebro University, School of Science and Technology. Saab Dynamics Development, Karlskoga, Sweden.ORCID iD: 0000-0003-3298-502X
Örebro University, School of Science and Technology.ORCID iD: 0000-0003-1408-2249
Örebro University, School of Science and Technology.ORCID iD: 0000-0003-1655-0392
2016 (English)In: 26th CIRP Design Conference, Amsterdam: Elsevier, 2016, p. 246-251Conference paper, Published paper (Refereed)
Abstract [en]

3D-printing has been used to create prototypes during the development phase for more than 20 years. Now, functional parts can be printed directly in specific metal powders using similar layer-by-layer techniques. The additive method is unlike traditional mass production manufacturing methods in many ways, creating new possibilities for designers to realise new and different design ideas previously impossible to manufacture. When products are mass produced, there is a desire to improve manufacturability. This is traditionally done by a designer with knowledge about certain manufacturing methods altering design choices to make it cheaper to manufacture.

This paper shows different design for AM (DfAM) methods where performance and part cost are both of interest. It adds to existing research by classifying design for additive manufacturing in two different classes; process-driven and designer-driven shaping of parts. A cost-prediction model for Selective Laser Melting (SLM) printed parts is suggested as an initial step to choose parts for redesign from an economical perspective. A case study of a missile launcher beam redesigned for additive manufacturing using three different approaches is presented. Differences and similarities in design methods are discussed and the redesigned parts are compared for mass and cost. It is shown that redesigning for AM can reduce mass but depending on part size and print speed, the part can become more expensive than the original design, creating a need to know the customer value of what the redesigned part provides, in this case, the value of reduced mass.

Place, publisher, year, edition, pages
Amsterdam: Elsevier, 2016. p. 246-251
Series
Procedia CIRP, ISSN 2212-8271 ; 50
Keywords [en]
Additive manufacturing, Powder Bed Fusion, design, topology optimisation, lattices, DfAM
National Category
Mechanical Engineering
Identifiers
URN: urn:nbn:se:oru:diva-53930DOI: 10.1016/j.procir.2016.04.150ISI: 000387666600041Scopus ID: 2-s2.0-84986631521OAI: oai:DiVA.org:oru-53930DiVA, id: diva2:1055834
Conference
26th CIRP Design Conference, KTH Royal Institute of Technology, Stockholm, Sweden, June 15-17, 2016
Available from: 2016-12-13 Created: 2016-12-13 Last updated: 2018-07-17Bibliographically approved
In thesis
1. Some aspects on designing for metal Powder Bed Fusion
Open this publication in new window or tab >>Some aspects on designing for metal Powder Bed Fusion
2017 (English)Licentiate thesis, comprehensive summary (Other academic)
Abstract [en]

Additive Manufacturing (AM) using the Powder Bed Fusion (PBF) is a relatively new manufacturing method that is capable of creating shapes that was previously practically impossible to manufacture. Many think it will revolutionize how manufacturing will be done in the future. This thesis is about some aspects of when and how to Design for Additive Manufacturing (DfAM) when using the PBF method in metal materials. Designing complex shapes is neither easy nor always needed, so when to design for AM is a question with different answers depending on industry or product. The cost versus performance is an important metric in making that selection. How to design for AM can be divided into how to improve performance and how to improve additive manufacturability where how to improve performance once depends on product, company and customer needs. Using advanced part shaping techniques like using Lattices or Topology Optimization (TO) to lower part mass may increase customer value in addition to lowering part cost due to faster part builds and less powder and energy use. Improving PBF manufacturability is then warranted for parts that reach series production, where determining an optimal build direction is key as it affects many properties of PBF parts. Complex shapes which are designed for optimal performance are usually more sensitive to defects which might reduce the expected performance of the part. Non Destructive Evaluation (NDE) might be needed to certify a part for dimensional accuracy and internal defects prior use. The licentiate thesis covers some aspects of both when to DfAM and how to DfAM of products destined for series production. It uses design by Lattices and Topology Optimization to reduce mass and looks at the effect on part cost and mass. It also shows effects on geometry translation accuracies from design to AM caused by differences in geometric definitions. Finally it shows the effect on how different NDE methods are capable of detecting defects in additively manufactured parts.

Place, publisher, year, edition, pages
Örebro: Örebro University, 2017. p. 80
Series
Örebro Studies in Technology, ISSN 1650-8580 ; 74
Keywords
Additive Manufacturing, AM, DfAM, lattice, Powder Bed Fusion, Topology optimization, Selective Laser Melting, Electron Beam Melting, Design for manufacturability
National Category
Other Mechanical Engineering
Identifiers
urn:nbn:se:oru:diva-62947 (URN)
Presentation
2017-11-29, Örebro universitet, Prismahuset, sal P258, Fakultetsgatan 1, Örebro, 13:15 (English)
Opponent
Supervisors
Available from: 2017-12-05 Created: 2017-12-05 Last updated: 2017-12-05Bibliographically approved

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Hällgren, SebastianPejryd, LarsEkengren, Jens

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