Additive manufacturing-enabled design theory and methodology: a critical review

Abstract

As additive manufacturing (AM) process evolves from rapid prototyping to the end-of-use product manufacturing process, manufacturing constraints have largely been alleviated and design freedom has been significantly broadened, including shape complexity, material complexity, hierarchical complexity, and functional complexity. Inevitably, conventional Design Theory and Methodology (DTM) especially life-cycle objectives oriented ones are challenged. In this paper, firstly, the impact of AM on conventional DTM is analyzed in terms of design for manufacturing (DFM), design for assembly (DFA), and design for performance (DFP). Abundance of evidences indicate that conventional DTM is not qualified to embrace these new opportunities and consequently underline the need for a set of design principles for AM to achieve a better design. Secondly, design methods related with AM are reviewed and classified into three main groups, including design guidelines, modified DTM for AM, and design for additive manufacturing (DFAM). The principles and representative design methods in each category are studied comprehensively with respect to benefits and drawbacks. A new design method partially overcoming these drawbacks by integrating function integration and structure optimization to realize less part count and better performance is discussed. Design tools as a necessary part for supporting design are also studied. In the meantime, the review also identified the possible areas for future research.

3D printing of functional anatomical insoles

“…It is therefore necessary to adapt traditional design methodologies to additive manufacturing through the DFAM (Design For Additive Manufacturing) paradigm. [7] defined DFAM as a set of shapes, sizes, material compounds, geometric mesostructures and microstructures to take full advantages of the possibilities of this production method, in such a way that the original design is implemented to reduce costs and produce objects that were unfeasible before. One of the most popular additive manufacturing techniques is 3D printing by Fused Deposition Modelling (FDM).…”

“…For example, hollow areas can be defined in the insole design, which will modify the insole functionality in terms of shock absorption, flexibility, etc. Therefore, additive manufacturing alleviates many of the constraints derived from the use of the Design for Manufacturing (DFM) paradigm [7]. Under this paradigm, the designer is to create the design always taking into account the limitations established by the manufacturing system.…”

Challenges of additive manufacturing technologies from an optimisation perspective

“…The paper by Yang and Zhao [3] report one of the most recent review on AM-enabled design, which is the closest subject to topology optimisation. In their review, design guidelines are exposed and the focus on structure optimisation methodology is explored through different contributions.…”

“…Additive Manufacturing (AM) is a collection of versatile techniques of rapid prototyping that allow material design from 3D digital models [1][2][3]. The term AM comes also under different other nicknames such as direct digital manufacturing or solid freeform fabrication [4,5].…”

“…In addition, one major advantage of AM reported in the literature is the ability to process complex shapes that are not easy to design using traditional ways such as extrusion and moulding [3,41,42]. AM potential, as a leading design technique, is enormous and the related applications are huge [7,[43][44][45][46][47].…”