Designers around the world have leveraged the rapid prototyping and manufacturing capabilities of additive manufacturing (AM), commonly known as 3D printing, to develop numerous engineering design solutions for the COVID-19 pandemic. This dataset consists of the design and manufacturability data for twenty-six such engineering design solutions spanning three categories: (1) face masks (N = 12), (2) face shields (N = 6), and (3) hands-free door openers (N = 8). The designs were collected from open-source websites such as Thingiverse, GrabCAD, and the NIH 3D Print Exchange. The manufacturability of these designs was simulated using Ultimaker Cura software and three measures were obtained: (1) build time, (2) build cost, and (3) build material. Furthermore, these simulations were performed for multiple materials and infill densities for comparison. Additionally, the manufacturing cost using injection molding was simulated using the Cost Estimation Tool in Solidworks. This dataset comprises (1) the STL files for the designs, (2) the simulated manufacturability data (for additive manufacturing and injection molding), and (3) images that depict the build orientation used in these manufacturability simulations. This dataset can facilitate the development of future innovations that leverage the capabilities of AM processes. Furthermore, this dataset can be used by designers and manufacturers to compare solutions and choose appropriate ones for manufacturing.
Purpose
The COVID-19 pandemic has resulted in numerous innovative engineering design solutions, several of which leverage the rapid prototyping and manufacturing capabilities of additive manufacturing. This paper aims to study a subset of these solutions for their utilization of design for AM (DfAM) techniques and investigate the effects of DfAM utilization on the creativity and manufacturing efficiency of these solutions.
Design/methodology/approach
This study compiled 26 COVID-19-related solutions designed for AM spanning three categories: (1) face shields (N = 6), (2) face masks (N = 12) and (3) hands-free door openers (N = 8). These solutions were assessed for (1) DfAM utilization, (2) manufacturing efficiency and (3) creativity. The relationships between these assessments were then computed using generalized linear models to investigate the influence of DfAM utilization on manufacturing efficiency and creativity.
Findings
It is observed that (1) unique and original designs scored lower in their AM suitability, (2) solutions with higher complexity scored higher on usefulness and overall creativity and (3) solutions with higher complexity had higher build cost, build time and material usage. These findings highlight the need to account for both opportunistic and restrictive DfAM when evaluating solutions designed for AM. Balancing the two DfAM perspectives can support the development of solutions that are creative and consume fewer build resources.
Originality/value
DfAM evaluation tools primarily focus on AM limitations to help designers avoid build failures. This paper proposes the need to assess designs for both, their opportunistic and restrictive DfAM utilization to appropriately assess the manufacturing efficiency of designs and to realize the creative potential of adopting AM.
Designers from around the world have proposed numerous engineering design solutions for problems related to the COVID-19 pandemic, many of which leverage the rapid prototyping and manufacturing capabilities of additive manufacturing (AM). While some of these solutions are motivated by complex and urgent requirements (e.g., face masks), others are motivated by simpler and less urgent needs (e.g., hands-free door openers). Previous research suggests that problem definition influences the creativity of solutions generated for it. In this study, we investigate the relationship between the definition of problems related to the COVID-19 pandemic and the characteristics of AM solutions that were openly shared for these problems. Specifically, we analyze 26 AM solutions spanning three categories: (1) hands-free door openers (low complexity problem), (2) face shields (moderate complexity problem), and (3) face masks (high complexity problem). These designs were compared on (1) DfAM utilization, (2) manufacturability (i.e., build time, cost, and material usage), and (3) creativity. We see that the solutions designed for the high complexity problem, i.e., face masks, were least suitable for AM. Moreover, we see that solutions designed for the moderate complexity problem, i.e., face shields, had the lowest build time, build cost, and material consumption. Finally, we observe that the problem definition did not relate to the creativity of the AM solutions. In light of these findings, designers must sufficiently emphasize the AM suitability and manufacturability of their solutions when designing for urgent and complex problems in rapid response situations.
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