A new DFM approach to combine machining and additive manufacturing

Design For Manufacturing (DFM) approaches aim to integrate manufacturability aspects during the design stage. Most of DFM approaches usually consider only one manufacturing process, but products competitiveness may be improved by designing hybrid modular products, in which products are seen as 3-D puzzles with modules realized aside by the best manufacturing process and further gathered. A new DFM system is created in order to give quantitative information during the product design stage of which modules will benefit in being machined and which ones will advantageously be realized by an additive process (such as Selective Laser Sintering or laser deposition). A methodology for a manufacturability evaluation in case of a subtractive or an additive manufacturing process is developed and implemented in a CAD software. Tests are carried out on industrial products from automotive industry

Fused Deposition Modeling Printed Patterns for Sand Casting in a Nigerian Foundry: A Review

There has been a gradual adoption of Three-Dimensional (3D) printing in pattern making for sand casting absolutely because of its reduced lead-time and higher dimensional accuracy.Pattern making is the most central activity in the production line of any casting operation. A delay in pattern making or a defect in pattern usually translates to increased production cost and time or poor quality castings respectively. Many foundry industries have been concerned with reducing the duration for pattern making and improving the dimensional accuracy of patterns. Adoption of Fused Deposition Modeling (FDM) based patterns have only provided a limited solution to the challenges of traditional pattern making for sand casting.Some patterns are not suitable for FDM printing due to their size volume which is not usually cost-effective to print. Also,the surface quality and mechanical properties of patterns produced with FDM are usually affected by process parameters thereby leading to post-manufacturing treatment before the patterns are suitable for moulding operation. This study investigated the problems of traditional pattern making and the challenges of FDM-printed PLA-patterns for sand casting and suggested solutions and areas for future research. Related researches on 3D printing in the foundry carried out around the worldwide are discussed

Assessing additive and subtractive manufacturing technologies for the production of tools in the automotive industry

Tooling is an integral component to the traditional manufacturing cycle, despite the fact that it’s both costly and time-consuming to produce. Additive manufacturing (AM) is currently considered viable in certain instances, often competing against subtractive manufacturing in the delivery of tools, on time, with the required quality. This paper considers the use of AM and computer numerical control (CNC) machining to manufacture an insert for the tooling of a vehicle headlight adjuster clip. The proposed methodology for manufacturing the insert is composed of two manufacturing techniques: AM using selective laser melting (SLM) technology and CNC milling. The tool material used to manufacture the inserts in both cases is Stainless Steel 316L, whilst the injected parts are manufactured in polypropylene. Performance tests were applied to each of the two inserts in the context of material chemical composition, microstructure, hardness, surface roughness, and dimensional accuracy. Furthermore, the injected parts produced were tested to determine dimensional accuracy, quality and functionality. Finally, it was concluded that both the SLM insert and CNC machined insert successfully produced functional parts. Moreover, the products from the SLM tool insert were more accurate dimensionally, but in terms of surface finish, the CNC product was perceived to be better quality

Design for Wire + Arc Additive Manufacture: design rules and build orientation selection

Wire + Arc Additive Manufacture (WAAM) is an additive manufacturing technology that can produce near net-shape parts layer by layer in an automated manner using welding technology controlled by a robot or CNC machine. WAAM has been shown to produce parts with good structural integrity in a range of materials including titanium, steel and aluminium and has the potential to produce high value structural parts at lower cost with much less waste material and shorter lead times that conventional manufacturing processes. This paper provides an initial set of design rules for WAAM and presents a methodology for build orientation selection for WAAM parts. The paper begins with a comparison between the design requirements and capabilities of WAAM and other additive manufacturing technologies, design guidelines for WAAM are then presented based on experimental work. A methodology to select the most appropriate build orientation for WAAM parts is then presented using a multi attribute decision matrix approach to compare different design alternatives. Two aerospace case study parts are provided to illustrate the methodology

3D printing strategic deployment: the supply chain perspective

Purpose – The emergence and application of 3D Printing (3DP) is changing the way products are developed and reach the customer, allowing for unprecedented customisation options. Past research has focused on the modus operandi of the technology, providing indications for wider future adoption. 3DP is predicted to complement current production processes and is anticipated to have a profound effect on the value chain, and therefore, on Supply Chain (SC) management. Management-related 3DP research has, however, been largely fragmented in terms of analysing the strategic deployment of 3DP and the corresponding effects on performance objectives. Design/methodology – The approach taken is a critical literature review, synthesizing and interpreting past research on cross-industry deployment of 3DP, including illustrative examples. This enabled the development of a framework of current stage knowledge. Findings – Building on past research we propose a conceptual framework to be used as a classification system for 3DP operations, based on process and SC level configurations across different industries. We discuss the potential impact on operations performance objectives and then highlight research gaps, proposing specific research avenues to enhance understanding of the effects of 3DP adoption on SCs. Practical implications – The proposed framework outlines strategic guidelines for 3DP and provides practitioners with the range of strategic options available for 3DP deployment and anticipated impacts on performance. Originality/Value – The framework can be used to map 3DP deployment at an operational level and to identify the likely impact on performance objectives. Relevant implications and a future research agenda are explored

Internal and External Involvements in Integrated Product Development: A Two-Step Clustering Approach

© 2017 The Authors. The term Integrated Product Development (IPD) has been introduced as a focus for cross-disciplinary research and can have several forms, or manifestations, with regard to the existing disciplines such as concurrent engineering and design for manufacturing. Of central importance to IPD is the interpretation of the term "integration", particularly with regard to internal and external elements. However, there is not yet an explicit understanding of an appropriate degree of integration, or involvement, with respect to its different forms, that can assure successful implementation of IPD frameworks in practice. Through a review and clustering of the literature, this paper aims to address this challenge

Remanufacturing de pièce par procédé additif et soustractif : Proposition méthodologique et cas d'études sur des potences de vélo

National audienceCe travail vise à développer une méthodologie permettant de contribuer à fermer la boucle de l'économie circulaire en reconfigurant des pièces mécaniques à l'aide d'outils de fabrication additive et soustractive. La reconfiguration des pièces se définit ici comme un processus par lequel des pièces en fin de vie sont modifiées pour rendre possible leur retour dans un état neuf prolongeant leur durée de vie, ces pièces sont ici utilisées dans une application similaire à leur utilisation première. Cette stratégie s'appuie sur les possibilités offertes par le remanufacturing et son utilisation comme un outil pour participer à la soutenabilité des systèmes de production

Lasers in additive manufacturing

Additive manufacturing is a topic of considerable ongoing interest, with forecasts predicting it to have major impact on industry in the future. This paper focusses on the current status and potential future development of the technology, with particular reference to the role of lasers within it. It begins by making clear the types and roles of lasers in the different categories of additive manufacturing. This is followed by concise reviews of the economic benefits and disadvantages of the technology, current state of the market and use of additive manufacturing in different industries. Details of these fields are referenced rather than expanded in detail. The paper continues, focusing on current indicators to the future of additive manufacturing. Barriers to its development, trends and opportunities in major industrial sectors, and wider opportunities for its development are covered. Evidence indicates that additive manufacturing may not become the dominant manufacturing technology in all industries, but represents an excellent opportunity for lasers to increase their influence in manufacturing as a whole

Design for additive manufacturing: Benefits, trends and challenges

In past five years, there has been a rapid increase in the publication on additive manufacturing (AM). Many technologies have been introduced in a rapidly growing market. The designers are confronted with many challenges in designing products for additive manufacturing. AM offers significant advantages, but there are also many constraints for AM to be used in its full potential. This paper explores trends, issues and challenges in design for AM, including associated costs, design options, quality considerations. It has been found that AM is in its infancy, there is insufficient understanding of the process, method, strategies, tools applied in design for additive manufacturing process, while process quality and capabilities are continuously improvin

Process Modeling Optimization in Additive Manufacturing Using Artificial Neural Networks

The need for production has roots in human life and its history. This date back to primitive days of human life, where he or she had to apply surrounding materials in order to manufacture the tools necessary for survival and durability against any insecurity. This was legitimizing the use of any means in order to obtain the tools and reach the goals at any cost. However, with human development primarily within the knowledge and understanding domain and also with the desire of humanity for best, expectations have risen. This was the time not only the cost mattered but also the simplicity of design, massive production, and diversity, less waste, autonomy, and implementation within a shorter time gained a higher momentum. On the other hand, the conventional manufacturing method was based on subtractive manufacturing with cutting and eliminating the unwanted sections or parts of an object. The disadvantage of such a method is that it requires a complicated production process design and is accompanied by waste. However, with the rise of additive manufacturing and three-dimensional printing equipment back in the 1980s, it became possible to build parts which could have almost any shape or geometry. Moreover, this also empowered the possibility of using digital and 3D models built by computer-aided design software. Simultaneously, on the other side, the foundation and application of artificial intelligence were maturing. This was due to the demand for machines to assist human beings in the domain of knowledge reasoning, learning, and planning. These were the pillars for making machines autonomous and to benefit from such features. Accordingly, this research work studies and overviews the applications and techniques of machine learning and artificial intelligence in the domain of additive manufacturing. It aims to determine the interaction of influential parameters on the process and to find the best solutions for improving the quality and mechanical features of manufactured parts. Moreover, this research tends to enable the experts to grasp a better understanding of AM process during manufacturing and additionally intends to infuse the experts' knowledge in additive manufacturing field utilizing the artificial neural network and finally generate a model with the ability of prediction and selection for promising results