Methods and tools for identifying and leveraging additive manufacturing design potentials

Kumke, Martin; Watschke, Hagen; Hartogh, Peter; Bavendiek, Ann-Kathrin; Vietor, Thomas

doi:10.1007/s12008-017-0399-7

Cited by 78 publications

(80 citation statements)

References 31 publications

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“…At present, no systematic consideration of the design potentials of multi-material AM, especially regarding electrically conductive structures, in product development is possible. There are only rudimentary frameworks [11] or general design heuristics for multi-material AM [12,13]. Moreover, design rules for MEX generally concern only geometrical restrictions [14] or consider process related influencing factors on mechanical properties [15].…”

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confidence: 99%

Design and Characterization of Electrically Conductive Structures Additively Manufactured by Material Extrusion

2019

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Multi-material additive manufacturing offers new design freedom for functional integration and opens new possibilities in innovative part design, for instance, a local integration of electrically conductive structures or heat radiant surfaces. Detailed experimental investigations on materials with three different fillers (carbon black (CB), carbon nanotubes (CNT) and nano copper wires) were conducted to identify process-specific influencing factors on electrical conductivity and resistive heating. In this regard, raster angle orientation, extrusion temperature, speed and flow rate were investigated. A variation of the raster angle (0 • , ±45 • , and 90 • ) shows the highest influence on resistivity. An angle of 0 • had the lowest electrical resistance and the highest temperature increase due to resistive heating. The material filled with nano copper wires showed the highest electrical conductivity followed by the CNT filled material and materials filled with CB. Both current-voltage characteristics and voltage-dependent heat distribution of the surface temperature were determined by using a thermographic camera. The highest temperature increase was achieved by the CNT filled material. The materials filled with CB and nano copper wires showed increased electrical resistance depending on temperature. Based on the experiments, solution principles and design rules for additively manufactured electrically conductive structures are derived. Appl. Sci. 2019, 9, 779 2 of 25 or casting), the designer has entirely new opportunities in product design. Consequently, there are two big challenges. On the one hand, the design engineer needs to be supported to ensure a consideration of these new design potentials in conceptual design. On the other hand, rules for designing conductive structures have to be established, for instance, to adjust the electrical resistance. The latter research gap is focused on in this contribution. Therefore, a simultaneous consideration of part design and process planning is crucial to leverage the advantages of AM's design freedom [9]. A provision of specific knowledge regarding AM's design potentials is essential for both, conceptual design (e.g., solution principles) and detail design (e.g., design rules) [10]. At present, no systematic consideration of the design potentials of multi-material AM, especially regarding electrically conductive structures, in product development is possible. There are only rudimentary frameworks [11] or general design heuristics for multi-material AM [12,13]. Moreover, design rules for MEX generally concern only geometrical restrictions [14] or consider process related influencing factors on mechanical properties [15]. However, no specific guidelines and rules for the design of additively manufactured conductive structures have been developed. Consequently, designers have no common basis on which functions such as electrical conductivity or heat radiation can be integrated in multi-material parts manufactured by MEX.Extensive experimental investigations were condu...

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confidence: 99%

Design and Characterization of Electrically Conductive Structures Additively Manufactured by Material Extrusion

2019

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“…Design for AM (DfAM) is field of research with many contributions in recent years [36][37][38][39]. Methods and guidelines have been proposed for different purposes, for example methods to inspire novel designs [39][40][41], guidelines for manufacturability with specific processes [42][43][44] or to generally guide in assessing suitable designs [45]. Kumke et al [36] categorize DfAM research into DfAM in the strict sense (concerning the design of the component) and DfAM in the broad sense (concerning part and process selection and manufacturability).…”

Section: Product Development With Additive Manufacturingmentioning

confidence: 99%

A Design for Qualification Framework for the Development of Additive Manufacturing Components—A Case Study from the Space Industry

Dordlofva

2020

Aerospace

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Additive Manufacturing (AM) provides several benefits for aerospace companies in terms of efficient and innovative product development. However, due to the general lack of AM process understanding, engineers face many uncertainties related to product qualification during the design of AM components. The aim of this paper is to further the understanding of how to cope with the need to develop process understanding, while at the same time designing products that can be qualified. A qualitative action research study has been performed, using the development of an AM rocket engine turbine demonstrator as a case study. The results show that the qualification approach should be developed for the specific application, dependent on the AM knowledge within the organization. AM knowledge is not only linked to the AM process but to the complete AM process chain. Therefore, it is necessary to consider the manufacturing chain during design and to develop necessary knowledge concurrently with the product in order to define suitable requirements. The paper proposes a Design for Qualification framework, supported by six design tactics. The framework encourages proactive consideration for qualification and the capabilities of the AM process chain, as well as the continuous development of AM knowledge during product development.

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“…The sheer scope and complexity of the sorts of knowledge, data and tools required for DFAM have spurred interest in knowledge management approaches for AM. For example, one such framework used a simple semantic network to link AM product designs to a limited set of "values" that they might possess (Kumke, Watschke, and Vietor 2016;Kumke et al 2017). While a valuable approach, the simplicity of a simple network likely limits its ability to capture detailed product information and support complex or highly specific queries addressed against the available data.…”

Section: Design For Additive Manufacturingmentioning

confidence: 99%

Interoperability of disparate engineering domain ontologies using basic formal ontology

Hagedorn

Smith

Krishnamurty

et al. 2019

Journal of Engineering Design

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As engineering applications require management of ever larger volumes of data, ontologies offer the potential to capture, manage, and augment data with the capability for automated reasoning and semantic querying. Unfortunately, considerable barriers hinder wider deployment of ontologies in engineering. Key among these is lack of a shared top-level ontology to unify and organize disparate aspects of the field and coordinate co-development of orthogonal ontologies.As a result, many engineering ontologies are limited to their scope, and functionally difficult to extend or interoperate with other engineering ontologies. This paper demonstrates how the use of a top-level ontology, specifically the Basic Formal Ontology (BFO), greatly facilitates interoperability of multiple engineering-related ontologies. We constructed a system of formal linked ontologies by re-engineering legacy ontologies to be conformant with BFO and developing new BFO-conformant ontologies to capture knowledge in the engineering design, enterprise, human factors, manufacturing, and application domain of additive manufacturing. The resulting Integrated Framework for Additively Manufactured Products (IFAMP), including the body knowledge instantiated on its basis, serve as the basis for a proposed Design with Additive Manufacturing Method (DAMM), which we believe can support the design of innovative products with semantically enhanced ideation tools and enhanced access to application domain knowledge.The method and its facilitation through the ontological framework are demonstrated using a case study in medicine.

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Methods and tools for identifying and leveraging additive manufacturing design potentials

Cited by 78 publications

References 31 publications

Design and Characterization of Electrically Conductive Structures Additively Manufactured by Material Extrusion

Design and Characterization of Electrically Conductive Structures Additively Manufactured by Material Extrusion

A Design for Qualification Framework for the Development of Additive Manufacturing Components—A Case Study from the Space Industry

Interoperability of disparate engineering domain ontologies using basic formal ontology

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