Design for Additive Manufacturing: A Systematic Review

Alfaify, Abdullah; Saleh, Mustafa; Abdullah, Fawaz M.; Al-Ahmari, Abdulrahman

doi:10.3390/su12197936

Cited by 98 publications

(34 citation statements)

References 189 publications

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“…Thus, it may not be possible to produce parts with existing designs directly using FIM unless some suitable design changes are made, and the processes are optimized. This is consistent with the findings from design for AM literature that a part designed for conventional manufacturing may not be optimal for producing using DAM [30,[60][61][62][63].…”

Section: Discussionsupporting

confidence: 90%

Assessing the Suitability of Freeform Injection Molding for Low Volume Injection Molded Parts: A Design Science Approach

et al. 2021

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Low-volume manufacturing remains a challenge, especially for parts that need to be injection-molded. Freeform injection molding (FIM) is a novel method that combines elements from direct additive manufacturing (DAM) and injection molding (IM) to resolve some of the challenges seen in low-volume injection molding. In this study, we use a design science approach to explore the suitability of FIM for the manufacturing of low volume injection-molded parts. We provide an overview of the benefits and limitations of traditional IM and discuss how DAM and indirect additive manufacturing (IAM) methods, such as soft tooling and FIM, can address some of the existing drawbacks of IM for short series production. A set of different parts was identified and assessed using a design science-based approach to demonstrate how to incubate FIM as a solution to address the challenges faced in short series production with IM. This initial process innovation was followed by solution refinement, involving the optimization of the FIM processes. Finally, a “cross-case” analysis was conducted using the framework of context, intervention, mechanism and outcomes to generate insights about the generalizability of the results. It is concluded that FIM combines the short lead-times, low start-up costs and design freedom of DAM with the versatility and scalability of IM to allow manufacturers to bring low volume products to the market faster, more cheaply and with lower risk, and to maintain the relevance of these products through easy customization and adaptations once they have been launched.

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Section: Discussionsupporting

confidence: 90%

Assessing the Suitability of Freeform Injection Molding for Low Volume Injection Molded Parts: A Design Science Approach

et al. 2021

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“…The elastic modulus of rPS was 1720 MPa and poison ratio was 0.35. The density of rPS was 1.045 g/cm 3 . For simulation, ANSYS ® 2020R2 version software was analysis the mechanical properties of the lattice structure, including maximum von Misses stress and maximum total deformation.…”

Section: Finite Element Analysismentioning

confidence: 99%

“…In this modern age, additive manufacturing (AM) is an advanced manufacturing method used in developing prototypes, parts of end-use, and tools for production line. AM is widely adopted by many industries such as aerospace, automotive and medical industries, due to its many benefit, such as shorter product development cycles, able to create component with complex geometry, and reduced fabrication cost and lead time [1][2] Component with cellular pattern usually fabricated using AM process due to its unique capacities in fabricating part with complex geometry which cannot made by traditional manufacturing process [3]. The Fuse Deposition Modelling (FDM) technology is one of the AM process that widely used because low cost, reliable and easy handle.…”

Section: Introductionmentioning

confidence: 99%

Finite Element Analysis Study on Lattice Structure Fabricated Recycled Polystyrene from Post-used Styrofoam Waste

Juarez¹,

Koay²,

Chan

et al. 2021

MATEC Web Conf.

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Lattice structure design widely applicable for 3D printed components. This research investigated the lattice structure with different shape and relative density using Finite Element Analysis (FEA) simulation. The material used for the lattice structure was the recycled polystyrene made from post-used Styrofoam. The research assessed the mechanical behaviour of lattice structure with either triangular prism and square prism with FEA simulation and numerical mathematical modelling, such as stiffness to-mass ratio, maximum von Misses stress and effective Young’s modulus. The finding FEA shows a good agreement with result from numerical mathematic modelling. The FEA results show lattice structure with triangular prism exhibited lowest value of maximum von Misses stress with maximum stiffness-to-mass value compared to lattice structure square prism. The finding from this work provided an early prediction on mechanical properties of lattice structure fabricated from recycled polystyrene.

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“…Laser powder bed fusion (L-PBF) produced components have garnered industrial acceptance for critical applications in recent years as a result of equipment advancements, improved performance characterization of the materials fabricated by this method, and a focus on design for additive manufacturing (AM) [ 1 ]. In the L-PBF process a laser heat source is used to melt a single layer of a component in a bed of free-flowing metal powder under an inert cover gas, typically pure argon or pure nitrogen.…”

Section: Introductionmentioning

confidence: 99%

Absorption of Nitrogen during Pulsed Wave L-PBF of 17-4 PH Steel

2021

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In the fabrication of 17-4 PH by laser powder bed fusion (L-PBF) the well-documented occurrence of large amounts of retained austenite can be attributed to an elevated concentration of nitrogen present in the material. While the effects of continuous wave (CW) laser processing on in-situ nitrogen absorption characteristics have been evaluated, power modulated pulsed wave (PW) laser processing effects have not. In this study the effects of PW L-PBF processing of 17-4 PH on nitrogen absorption, phase composition, and mechanical performance are explored using commercially available PW L-PBF equipment and compared to samples produced by CW L-PBF. PW L-PBF samples fabricated in cover gas conditions with varying amounts of nitrogen demonstrated reduced absorption levels compared to those produced by CW L-PBF with no effects on phase composition and minimal effects on mechanical performance.

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Design for Additive Manufacturing: A Systematic Review

Cited by 98 publications

References 189 publications

Assessing the Suitability of Freeform Injection Molding for Low Volume Injection Molded Parts: A Design Science Approach

Assessing the Suitability of Freeform Injection Molding for Low Volume Injection Molded Parts: A Design Science Approach

Finite Element Analysis Study on Lattice Structure Fabricated Recycled Polystyrene from Post-used Styrofoam Waste

Absorption of Nitrogen during Pulsed Wave L-PBF of 17-4 PH Steel

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