Automated design of additive manufactured flow components with consideration of overhang constraint

Biedermann, Manuel; Beutler, Patrick; Meboldt, Mirko

doi:10.1016/j.addma.2021.102119

Cited by 26 publications

(22 citation statements)

References 53 publications

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Section: Sustainable Circular 3d Printing Modelmentioning

confidence: 99%

“…The process allows the rapid construction of parts and models through the sintering (using a laser) of the material used in the printer, mainly the metal powders that are addressed in this study. In engineering, 3D printing allows to try out Sustainable circular 3D printing model new prototypes, even those with complex internal structures and geometries, and to address problems and find solutions to them, which is something that traditional methods just cannot offer (Biedermann et al, 2021). Products ready for use immediately after the printing process are expected to go directly to the testing stage, but these can be applied if they require any unique mechanical or thermal treatments for the use they are to be put to destination (Riquelme et al, 2022).…”

Section: Sustainable Circular 3d Printing Modelmentioning

confidence: 99%

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A sustainable circular 3D printing model for recycling metal scrap in the automotive industry

Nascimento

Nepomuceno

Caiado

et al. 2022

JMTM

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Purpose Industries and businesses are pursuing Industry 4.0 technologies as well as adopting a circular approach focused on improving manufacturing processes through the reduction of wastes, CO2 emissions and mineral exploration to mitigate the impact of climate change. In this sense, additive manufacturing (AM), often referred to as 3D printing, can play a key role in the closed-loop of operations. However, academics and practitioners have scarcely discussed the feasibility of implementing AM alongside circular economy (CE) practices, the techniques and methods that this would require, or how AM could benefit sustainability and circularity. To address these gaps, this paper proposes a novel circular sustainable 3D printing model for scrap recycling in the automotive industry.Design/methodology/approach The methodology uses a literature review-based approach followed by empirical research using metal scraps as the raw material for fabricating a powder to input a metal 3D printer for generating sustainable automotive components. A conceptual sustainable circular model for the automotive industry is proposed. Next, is conducted a focus group comprises AM and automotive industry experts for evaluations.Findings The results indicate that the proposed model can be used to reintroduce waste back into the manufacturing chain as raw material for the on-demand manufacture and supply of automotive components and that it may also have social and environmental implications.Originality/value This paper’s contributions are threefold: it explores the combined use of Industry 4.0 (I4.0), CE and sustainability in the automotive industry, develops a new model to support the circularity and sustainability of the scrap chain and proposes the use of AM as a catalyst of CE practices by reproducing recycled components with a 3D printer for prototypes or fully functioning components.

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Section: Sustainable Circular 3d Printing Modelmentioning

confidence: 99%

Section: Sustainable Circular 3d Printing Modelmentioning

confidence: 99%

A sustainable circular 3D printing model for recycling metal scrap in the automotive industry

Nascimento

Nepomuceno

Caiado

et al. 2022

JMTM

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“…Similar procedures can be defined to formalize the generation of other design features, such as sacrificial supports, integrated supports, and detailed features such as interface elements. In this regard, the reader is referred to a prior work of the authors, which describes rule-based procedures for these design features [62].…”

Section: Formalization Of Knowledge (Step 4)mentioning

confidence: 99%

“…For this purpose, additional design features are developed to generate both support types automatically. These features are implemented like the flow channels by capturing the required design knowledge and automating the corresponding tasks using rule-driven procedures (see details in prior work [62]). The final output is a production-ready 3D part geometry of the flow manifold.…”

Section: Implementation Of Design Features (Step 5)mentioning

confidence: 99%

Automated Knowledge‐Based Design for Additive Manufacturing: A Case Study with Flow Manifolds

Biedermann

Beutler

Meboldt

2022

Chemie Ingenieur Technik

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Additive manufacturing (AM) enables novel process equipment devices. However, the manual 3D design of complex part geometries is frequently challenging as designers need to fulfill functional requirements and consider the restrictions of AM. One promising approach is to automatically generate the design of parts. This work aims to introduce such an automated design approach to practitioners in the area of process engineering. The work describes the basic steps required to develop an automated, knowledge‐based design tool for AM and demonstrates the approach using a case study on flow manifolds.

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“…DfAM is proposed to take full advantage of the manufacturing capacity to achieve better performance while meeting the requirements of AM, which requires the designers to add AM direction, support structures, size limitations, and so on, as the design constraints [34][35][36]. For instance, Biedermann et al [37] proposed a CAD-based design method for AM flow channels to meet the AM overhang constraint. This method can avoid most support structures by changing the cross-section shape and the AM direction.…”

Section: Am In the Fabrication Of Optimized Flow Channelsmentioning

confidence: 99%

Intelligent Design Optimization System for Additively Manufactured Flow Channels Based on Fluid–Structure Interaction

Zou

et al. 2022

Micromachines

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Based on expert system theory and fluid–structure interaction (FSI), this paper suggests an intelligent design optimization system to derive the optimal shape of both the fluid and solid domain of flow channels. A parametric modeling scheme of flow channels is developed by design for additive manufacturing (DfAM). By changing design parameters, a series of flow channel models can be obtained. According to the design characteristics, the system can intelligently allocate suitable computational models to compute the flow field of a specific model. The pressure-based normal stress is abstracted from the results and transmitted to the solid region by the fluid–structure (FS) interface to analyze the strength of the structure. The design space is obtained by investigating the simulation results with the metamodeling method, which is further applied for pursuing design objectives under constraints. Finally, the improved design is derived by gradient-based optimization. This system can improve the accuracy of the FSI simulation and the efficiency of the optimization process. The design optimization of a flow channel in a simplified hydraulic manifold is applied as the case study to validate the feasibility of the proposed system.

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Automated design of additive manufactured flow components with consideration of overhang constraint

Cited by 26 publications

References 53 publications

A sustainable circular 3D printing model for recycling metal scrap in the automotive industry

A sustainable circular 3D printing model for recycling metal scrap in the automotive industry

Automated Knowledge‐Based Design for Additive Manufacturing: A Case Study with Flow Manifolds

Intelligent Design Optimization System for Additively Manufactured Flow Channels Based on Fluid–Structure Interaction

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