4: Design for Additive Manufacturing
- Page ID
- 46531
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\(\newcommand{\avec}{\mathbf a}\) \(\newcommand{\bvec}{\mathbf b}\) \(\newcommand{\cvec}{\mathbf c}\) \(\newcommand{\dvec}{\mathbf d}\) \(\newcommand{\dtil}{\widetilde{\mathbf d}}\) \(\newcommand{\evec}{\mathbf e}\) \(\newcommand{\fvec}{\mathbf f}\) \(\newcommand{\nvec}{\mathbf n}\) \(\newcommand{\pvec}{\mathbf p}\) \(\newcommand{\qvec}{\mathbf q}\) \(\newcommand{\svec}{\mathbf s}\) \(\newcommand{\tvec}{\mathbf t}\) \(\newcommand{\uvec}{\mathbf u}\) \(\newcommand{\vvec}{\mathbf v}\) \(\newcommand{\wvec}{\mathbf w}\) \(\newcommand{\xvec}{\mathbf x}\) \(\newcommand{\yvec}{\mathbf y}\) \(\newcommand{\zvec}{\mathbf z}\) \(\newcommand{\rvec}{\mathbf r}\) \(\newcommand{\mvec}{\mathbf m}\) \(\newcommand{\zerovec}{\mathbf 0}\) \(\newcommand{\onevec}{\mathbf 1}\) \(\newcommand{\real}{\mathbb R}\) \(\newcommand{\twovec}[2]{\left[\begin{array}{r}#1 \\ #2 \end{array}\right]}\) \(\newcommand{\ctwovec}[2]{\left[\begin{array}{c}#1 \\ #2 \end{array}\right]}\) \(\newcommand{\threevec}[3]{\left[\begin{array}{r}#1 \\ #2 \\ #3 \end{array}\right]}\) \(\newcommand{\cthreevec}[3]{\left[\begin{array}{c}#1 \\ #2 \\ #3 \end{array}\right]}\) \(\newcommand{\fourvec}[4]{\left[\begin{array}{r}#1 \\ #2 \\ #3 \\ #4 \end{array}\right]}\) \(\newcommand{\cfourvec}[4]{\left[\begin{array}{c}#1 \\ #2 \\ #3 \\ #4 \end{array}\right]}\) \(\newcommand{\fivevec}[5]{\left[\begin{array}{r}#1 \\ #2 \\ #3 \\ #4 \\ #5 \\ \end{array}\right]}\) \(\newcommand{\cfivevec}[5]{\left[\begin{array}{c}#1 \\ #2 \\ #3 \\ #4 \\ #5 \\ \end{array}\right]}\) \(\newcommand{\mattwo}[4]{\left[\begin{array}{rr}#1 \amp #2 \\ #3 \amp #4 \\ \end{array}\right]}\) \(\newcommand{\laspan}[1]{\text{Span}\{#1\}}\) \(\newcommand{\bcal}{\cal B}\) \(\newcommand{\ccal}{\cal C}\) \(\newcommand{\scal}{\cal S}\) \(\newcommand{\wcal}{\cal W}\) \(\newcommand{\ecal}{\cal E}\) \(\newcommand{\coords}[2]{\left\{#1\right\}_{#2}}\) \(\newcommand{\gray}[1]{\color{gray}{#1}}\) \(\newcommand{\lgray}[1]{\color{lightgray}{#1}}\) \(\newcommand{\rank}{\operatorname{rank}}\) \(\newcommand{\row}{\text{Row}}\) \(\newcommand{\col}{\text{Col}}\) \(\renewcommand{\row}{\text{Row}}\) \(\newcommand{\nul}{\text{Nul}}\) \(\newcommand{\var}{\text{Var}}\) \(\newcommand{\corr}{\text{corr}}\) \(\newcommand{\len}[1]{\left|#1\right|}\) \(\newcommand{\bbar}{\overline{\bvec}}\) \(\newcommand{\bhat}{\widehat{\bvec}}\) \(\newcommand{\bperp}{\bvec^\perp}\) \(\newcommand{\xhat}{\widehat{\xvec}}\) \(\newcommand{\vhat}{\widehat{\vvec}}\) \(\newcommand{\uhat}{\widehat{\uvec}}\) \(\newcommand{\what}{\widehat{\wvec}}\) \(\newcommand{\Sighat}{\widehat{\Sigma}}\) \(\newcommand{\lt}{<}\) \(\newcommand{\gt}{>}\) \(\newcommand{\amp}{&}\) \(\definecolor{fillinmathshade}{gray}{0.9}\)- 4.0: Introduction
- This page explores Design for Additive Manufacturing (DfAM), which offers greater design freedom compared to traditional fabrication methods. It highlights challenges associated with DfAM, such as the need for careful planning to avoid post-processing issues. The chapter covers different additive manufacturing techniques, including metal powder bed fusion and polymer material extrusion, emphasizing the importance of designing viable parts for these processes.
- 4.1: Design Approach
- This page outlines the Additive Manufacturing (AM) Design Workflow, emphasizing the creation of detailed 3D models and the importance of build plans. It covers techniques like topology optimization and generative design to enhance material efficiency and structural integrity. The text discusses challenges in AM, including machine operation, material stress, and the need for process simulation. Different design approaches are mentioned (e.g.
- 4.2: Design Optimization- Implementation while considering build constraints
- This page discusses design principles and challenges in additive manufacturing (AM), focusing on powder bed fusion (PBF) and directed energy deposition (DED). It highlights the creation of complex geometries and the issues of production and inspection. The benefits and challenges of hybrid and conventional DED systems are examined, noting differences in methods, flexibility, and material use. Additionally, material extrusion is addressed regarding design constraints and finishing options.
- 4.3: AM Industry Design Challenges and Strategic Solutions
- This page discusses key learning objectives for software design in additive manufacturing (AM), addressing both technical and cultural challenges. It presents a four-phase maturity model for AM adoption: Phase 0 (rapid prototyping), Phase 1 (existing products), Phase 2 (integrating designs), Phase 3 (topology optimization), and Phase 4 (designing new products from scratch).
- 4.4: Summary
- This page explores key terms in Additive Manufacturing (AM) design, including Direct Part Conversion, MfAM, and DfAM. It highlights the transition from direct part conversion to DfAM, which can improve product performance and reduce assembly labor. DfAM encourages innovative concepts that leverage AM benefits, supported by generative design tools. While AM offers unique design opportunities, it also poses challenges like inspection and certification.
- 4.5: Review Questions
- This page discusses Additive Manufacturing (AM), covering key aspects such as Direct Part Conversion, MfAM, and DfAM distinctions; the importance of build plans and orientation; a DfAM exercise guide; suitable AM systems; design tools for performance enhancement; methods to reduce support material; the advantages and disadvantages of DED systems; challenges with .STL files; software interoperability issues; and corporate reluctance to embrace DfAM.
- 4.6: Discussion Questions
- This page discusses the importance of distinguishing manufacturing techniques such as Direct Part Conversion and the differences between metallic DED and polymer SLS applications. It emphasizes the role of VOC in design and suggests scenarios for a hybrid DED system. Additionally, it encourages rationalization of Functionally Graded Materials in product design, explores ways to enhance the digital value chain, and examines the implications of company investments in design maturity.
- 4.7: Case Questions
- This page outlines tasks in product design and additive manufacturing, including disassembling a product, evaluating component orientation, conducting morphological analysis, and using a Pugh Concept Selection matrix. It suggests exploring lattice designs on Thingiverse, discussing cellular features in heat exchangers, and assessing a company's AM maturity. The page concludes with steps to enhance the company's AM capabilities for maximizing value.
- 4.8: Key Terms
- This page discusses design approaches and optimization strategies in additive manufacturing, covering methodologies like 3MF and generative design. It addresses design optimizations for build constraints through features like honeycomb and lattice structures. The text also highlights challenges, particularly software interoperability, and calls for strategic solutions to improve design processes and production efficiency.