Development of a design feature database to support design for additive manufacturing (DfAM)

This research introduces a method to aid the design of products or parts to be made using Additive Manufacturing (AM), particularly the laser sintering (LS) system. The research began with a literature review that encompassed the subjects of design and AM and through this the need for an assistive design approach for AM was identified. Undertaking the literature review also confirmed that little has been done in the area of supporting the design of AM parts or products. Preliminary investigations were conducted to identify the design factors to consider for AM. Two preliminary investigations were conducted, the first investigation was conducted to identify the reasons for designing for AM, the need for a design support tool for AM and current challenges of student industrial designers designing parts or products for AM, and also to identify the type of design support they required. Further investigation were conducted to examine how AM products are developed by professional industrial designers and to understand their design processes and procedures. The study has identified specific AM enabled design features that the designers have been able to create within their case study products. Detailed observation of the case study products and parts reveals a number of features that are only economical or possible to produce with AM. A taxonomy of AM enabled design features was developed as a precursor for the development of a computer based design tool. The AM enabled design features was defined as a features that would be uneconomical or very expensive to be produced with conventional methods. The taxonomy has four top-level taxons based on four main reasons for using AM, namely user fit requirements, improved product functionality requirements, parts consolidation requirements and improvement of aesthetics or form requirements. Each of these requirements was expanded further into thirteen sub categories of applications that contained 106 examples of design features that are only possible to manufacture using AM technology. The collected and grouped design features were presented in a form of a database as a method to aid product design of parts or products for AM. A series of user trials were conducted that showed the database enabled industrial designers to visualise and gather design feature information that could be incorporated into their own design work. Finally, conclusions are drawn and suggestions for future work are listed. In summary, it can be concluded that this research project has been a success, having addressed all of the objectives that were identified at its outset. From the user trial results, it is clear to see that the proposed tool would be an effective tool to support product design for AM, particularly from an educational perspective. The tool was found to be beneficial to student designers to take advantage of the design freedom offered by AM in order to produce improved product design. As AM becomes more widely used, it is anticipated that new design features will emerge that could be included in future versions of the database so that it will remain a rich source of inspirational information for tomorrow s industrial designers

Development of a design feature database to support design for additive manufacturing (DfAM)

This research introduces a method to aid the design of products or parts to be made using Additive Manufacturing (AM), particularly the laser sintering (LS) system. The research began with a literature review that encompassed the subjects of design and AM and through this the need for an assistive design approach for AM was identified. Undertaking the literature review also confirmed that little has been done in the area of supporting the design of AM parts or products. Preliminary investigations were conducted to identify the design factors to consider for AM. Two preliminary investigations were conducted, the first investigation was conducted to identify the reasons for designing for AM, the need for a design support tool for AM and current challenges of student industrial designers designing parts or products for AM, and also to identify the type of design support they required. Further investigation were conducted to examine how AM products are developed by professional industrial designers and to understand their design processes and procedures. The study has identified specific AM enabled design features that the designers have been able to create within their case study products. Detailed observation of the case study products and parts reveals a number of features that are only economical or possible to produce with AM. A taxonomy of AM enabled design features was developed as a precursor for the development of a computer based design tool. The AM enabled design features was defined as a features that would be uneconomical or very expensive to be produced with conventional methods. The taxonomy has four top-level taxons based on four main reasons for using AM, namely user fit requirements, improved product functionality requirements, parts consolidation requirements and improvement of aesthetics or form requirements. Each of these requirements was expanded further into thirteen sub categories of applications that contained 106 examples of design features that are only possible to manufacture using AM technology. The collected and grouped design features were presented in a form of a database as a method to aid product design of parts or products for AM. A series of user trials were conducted that showed the database enabled industrial designers to visualise and gather design feature information that could be incorporated into their own design work. Finally, conclusions are drawn and suggestions for future work are listed. In summary, it can be concluded that this research project has been a success, having addressed all of the objectives that were identified at its outset. From the user trial results, it is clear to see that the proposed tool would be an effective tool to support product design for AM, particularly from an educational perspective. The tool was found to be beneficial to student designers to take advantage of the design freedom offered by AM in order to produce improved product design. As AM becomes more widely used, it is anticipated that new design features will emerge that could be included in future versions of the database so that it will remain a rich source of inspirational information for tomorrow s industrial designers.EThOS - Electronic Theses Online ServiceGBUnited Kingdo

A Methodical Approach to Support Conceptual Design for Multi-Material Additive Manufacturing

Additive manufacturing (AM) opens new possibilities for innovative product designs. However, due to a lack of knowledge and restrained creativity because of design fixations, design engineers do not take advantage of AM's design freedom. Especially multi-material AM provides new opportunities for functional integration that hardly considered in ideation. To overcome barriers in the development of solution ideas and utilizing such new design potentials, new design methods and tools are needed. Therefore, in this contribution, a methodological approach for a function-oriented provision of solution principles specific to material extrusion is presented. A tool is developed to facilitate effective guidance in developing solution ideas and to foster a realistic concretization by providing a combination of opportunistic and restrictive AM knowledge. Besides general levers of AM, process-specific design opportunities support the design engineers in exploiting AM's potentials, especially those who are not familiar with Design for AM. Finally, the applicability of the methodological approach is evaluated in an academic study by means of redesigning a hand prosthesis with a grab function

Design Principle for Additive Manufacturing: Direct Metal Sintering

Additive Manufacturing (AM) brought new design possibilities and freedom to the product design process. However, as the existing design rules and design limitations do not apply to the AM, designers require new methods and tools to utilise the full potential of AM. The stated is especially noticeable in the design of metal products made with AM, particularly with the Direct Metal Laser Sintering (DMLS) process. The research proposes a methodological approach for analysing the existing DMLS products made with DMLS to extract design knowledge. The methodology is applied to the pool of DMLS from which 15 design principles are extracted that formalise design knowledge about DMLS. The design principles are intended to be used in the early design stages of the design process as a source of design knowledge and inspiration for conceptualising new and innovative products that will be made using DMLS

Feasibility study of vacuum technology integrated fused deposition modeling to reduce staircase effect

Fused deposition modeling (FDM) is currently one of the most used AM technologies and has been around in various industries since its tremendous offering. Most semi-molten layered thermoplastic surface often uneven, which lead to rough and poor surface finish. The FDM process involves temperature gradient since the material extrude was in a semi-molten state. The thermal stresses present and affect the surface quality. This paper proposes an idea of using vacuum technology to reduce the “staircase effect” parts printed. The FDM machine remains in a rectangular acrylic chamber, an oil-flooded-vacuum pump connected will absorb the air inside the chamber until desire pressure while printing object. Mitutoyo SJ-301 portable surface roughness tester and optical microscope used to analyze the quality of surface finish. Result reveal with vacuum technology, improve 9% from normal print.Keywords: fused deposition modeling; simulation; vacuum technology; surface finis

A design framework for additive manufacturing based on the integration of axiomatic design approach, inverse problem-solving and an additive manufacturing database

Additive manufacturing has emerged as an integral part of modern manufacturing because of its unique capabilities and has already found its application in various domains like aerospace, automotive, medicine and architecture. In order to take the full advantage of this breakthrough manufacturing technology, it is imperative that practical design frameworks or methodologies are developed and consequently, Design for Additive Manufacturing (DfAM) has risen to provide a set of guidelines during the product design process. The existing DfAM methods have certain limitations in that the additive manufacturing process capabilities are not taken into consideration in the early design stage effectively and most of them rely on direct application of existing methods for conventional manufacturing. Furthermore, there is a lack of DfAM methods suitable for additive manufacturing novices. To tackle these issues, this study develops a design framework for additive manufacturing through the integration of axiomatic design approach and theory of inventive problem-solving (TRIZ) with the consideration of additive manufacturing environment. This integrated approach is effective because axiomatic design approach can be used to systematically define and analyze the problem, while the inverse problem-solving approach of TRIZ combined with an additive manufacturing database can be used as an idea generation tool that can generate innovative solutions. Finally, two case studies are presented to validate the proposed design framework

PENGEMBANGAN SISTEM DATABASE BERBASIS TRI DARMA PERGURUAN TINGGI PADA PROGRAM STUDI PENDIDIKAN EKONOMI

Abstract: Document management is important for organizations so that documents have good use value. Document management systems are sometimes only run at the parent institution centrally but are not implemented well at low management levels. This research is a development research with a development model design that is used as a reference in this research is the modified Borg and Gall development design. The research subject is the Satya Wacana Christian University undergraduate economic education study program. Data collection techniques using observation, interviews, expert judgment. The instrument used is an interview sheet, observation checklist. expert validation sheets and questionnaires. The results of this study indicate that the Education Database System created has the following feasibility test results: media experts get a rating of 4 in the "Good" category, practitioners get a 4.4 rating in the "Very Good" category, and from obtaining a 4.47 rating in the "Good" category. “Very Good” category. From several feasibility tests conducted, it was concluded that the database system from the media, practitioners, and users perspective was feasible to be applied. Trials in administrative activities show that the database system can assist administrative activities in the Economics Education S1 study program, so this database system is appropriate to be used as a system to assist administrative management in the study program. Through the database system developed, it is hoped that it can become an embryo for improving the administrative system, especially at the low management level. In further research, the database system can be developed according to the needs of other educational institutions.Keywords: Database System; Tri Dharma College; Economic Education Abstrak: Pengelolaan dokumen merupakan hal yang penting bagi organisasi agar dokumen memiliki nilai guna yang baik. Sistem pengelolaan dokumen terkadang hanya dijalankan pada lembaga induk secara terpusat namun tidak terlaksana dengan baik pada level low management. Penelitian ini merupakan penelitian pengembangan dengan desain model pengembangan yang menjadi acuan dalam penelitian ini adalah desain pengembangan Borg and Gall yang telah dimodifikasi. Subjek penelitian yang diambil adalah program studi S1 pendidikan ekonomi Universitas Kristen Satya Wacana. Teknik pengumpulan data menggunakan observasi, wawancara, penilaian pakar. Instrumen yang digunakan adalah lembar wawancara, ceklish observasi. lembar validasi pakar dan angket. Hasil penelitian ini menunjukkan bahwa Sistem Database Pendidikan yang dibuat memiliki hasil uji kelayakan sebagai berikut ini: ahli media memperoleh penilaian 4 dalam kategori “Baik”, praktisi memperoleh penilaian 4,4 dalam kategori “Sangat Baik”, dan dari memperoleh penilaian 4,47 dalam kategori “Sangat Baik”. Dari beberapa uji kelayakan yang dilakukan disimpulkan bahwa sistem database dari segi media, praktisi, dan pengguna layak untuk dapat diterapkan. Uji coba dalam kegiatan administrasi menunjukkan bahwa sistem database dapat membantu kegiatan administrasi pada program studi S1 Pendidikan Ekonomi, sehingga sistem database ini layak digunakan sebagai sistem untuk membantu pengelolaan administrasi pada program studi. Melalui sistem database yang dikembangkan ini diharapkan dapat menjadi embrio untuk perbaikan sistem administrasi terkhusus pada level low management. Pada penelitian lanjutan sistem database dapat dikembangkan sesuai dengan kebutuhan lembaga pendidikan yang lain.Kata kunci: Sistem Database; Tri Darma Perguruan Tinggi; Pendidikan Ekonom

Investigating the Links between the Process Parameters and Their Influence on the Aesthetic Evaluation of Selective Laser Melted Parts

This study is a precursor to gaining a deeper understanding of how each parameter of the Additive Manufacturing (AM) process influences the aesthetic properties of 3D printed products. Little research has been conducted on this specific aspect of AM. Using insights from the work presented in this paper, we intend to develop design support tools to give the designer more control over the printed products in terms of aesthetics. In this initial work, we fabricated samples using Selective Laser Melting (SLM) technology, and investigated the parameters geometry, building strategy, and post-processing. We asked participants to evaluate the visual and physical interaction with the manufactured samples. Results show that, in addition to geometry and post-processing, the aesthetic evaluation can also be strongly influenced by the SLM process’ building strategy. This understanding will enable us to develop tools to give designers more control over the part’s aesthetic appearance. In addition, we present a systematic procedure and setup to evaluate the aesthetic appearance of products manufactured using AM

Development and Implementation of a Guideline for the Combination of Additively Manufactured Joint Assemblies with Wire Actuators made of Shape Memory Alloys

Smart Materials actuators in the form of wires made of shape memory alloys in combination with additively manufactured carrier components are used in a wide variety of prototype developments of innovative joint assemblies. This combination is relevant because of the same manufacturing costs of the additively manufactured components, which are independent of the quantity of parts, the free geometric design possibilities as well as the huge energy density of the aforementioned actuator technology. In particular, the focus is on the possibility of appropriately fitting large wire lengths on a compact part volume while taking into account acceptable force losses. Since there is no design guideline for such joint developments, each is individual, which results in unnecessarily long development times and a higher risk of errors. Based on selected in-house and third-party examples, integration possibilities of shape memory alloy wire actuators in additively manufactured carrier components are analysed and transferred into a universally applicable design guideline. These recommendations are brought into the framework of existing design guidelines of the VDI (Verein Deutscher Ingenieure – Association of German Engineers), namely VDI 2206 and VDI 2221 with extensions for additive manufacturing, for a better usability and integrability into existing processes. Finally, this results in a simplified access to the topic of the combination of additive manufacturing and shape memory alloys and a more efficient realisation of such joint developments