Additive manufacturing integration with topology optimization methodology for innovative product design

A Deep Look at Metal Additive Manufacturing Recycling and Use Tools for Sustainability Performance

“…In the context of Industry 4.0, digitalisation of MAM has created opportunities to overcome design-related barriers of the novel production technologies and the new computational tools for simulation, visualisation, and instant analysis. These are the intelligent tools available to be included in an optimal industrial management system and sustainable value chain [23][24][25][26]. The digital tools, correlated with the principles of extended life cycle products based on the 6R concept (reduce, re-use, recover, re-design, recycle, re-manufacture) shape the path for the sustainability performance of the modern smart production.…”

“…In present conditions, many authors have considered that traditional manufacturing has a more substantial environmental impact than MAM [10,[12][13][14][15]. Important topics to be analysed are as follows: design for AM (DfAM), design for environment (DfE), repair and redesign, recycled material and waste, energy consumption and emissions, health and safety, topics highlighted for an entire lifecycle assessment (LCA) based on lifecycle inventories (LCIs), databases that are partially started to develop information in this topic area [20,[24][25][26][27]. These are important when sustainability performance is seen as a key factor for AM absorption in a wide range of industries.…”

“…Referring to sustainability, MAM could greatly reduce the waste in manufacturing, lowering energy consumption in the production of raw materials and in the processing steps, technological allowances, chips from subtractive processes, etc. However, the most critical part of MAM's widespread development is limited by many technical challenges that impede AM from being adopted, particularly in terms of metrology and standardisation, conditions very important for MAM use, recycling, repair, and re-manufacturing processes [15][16][17]21,25].…”

“…Hence, making the part optimised and integrating more specific features than possible with conventional processes allows for a low environmental impact of the product during its entire lifecycle. Design for environment (DfE) includes all environmental evaluations, especially considering materials and component (preferably modular) selection for a low environmental impact [21,23,25].…”

Design approaches for additive manufactured components, with a focus on selective laser melting

“…These benefits include reduction in manufacturing costs through lower material usage and shorter print times, and potential reduction in the component's distortions and residual stresses. Several tools and techniques have been widely adapted for lightweighting in AM design, including the use of topology, shape and size optimization, and inclusion of lattice structures [2,[5][6][7]. An example of how topology optimization can be used in component design is described in Figure 1, where a hydraulic valve block has been redesigned for Nurmi Cylinders Oy [8].…”