Design and characterisation of an additive manufacturing benchmarking artefact following a design-for-metrology approach

We present the design and characterisation of a high-speed sintering additive manufacturing benchmarking artefact following a design-for-metrology approach. In an important improvement over conventional approaches, the specifications and operating principles of the instruments that would be used to measure the manufactured artefact were taken into account during its design process. With the design-for-metrology methodology, we aim to improve and facilitate measurements on parts produced using additive manufacturing. The benchmarking artefact has a number of geometrical features, including sphericity, cylindricity, coaxiality and minimum feature size, all of which are measured using contact, optical and X-ray computed tomography coordinate measuring systems. The results highlight the differences between the measuring methods, and the need to establish a specification standards and guidance for the dimensional assessment of additive manufacturing parts

Skyport airframe: design and manufacturing

Many rural areas of developing countries lack the necessary transportation infrastructure to have reliable access to basic needs. This is particularly true for medical supplies. To combat the issue of insufficient access to vaccines in developing areas, the SkyPort project has developed the SkyPort UAV (Unmanned Aerial Vehicle). The SkyPort UAV has the vertical takeoff and landing (VTOL) capabilities of a quadcopter, as well as the efficient, sustained flight of a fixed-wing aircraft. It provides a cheaper, quicker, and safer delivery method than existing alternatives for vaccines in areas that lack a reliable transportation infrastructure. The role of the SkyPort Airframe Design Team was to design and build the primary support structure of the UAV, which will house the payload, controls, and propulsion systems being designed by the other two SkyPort teams. The airframe consists of a lightweight and durable fuselage, wing, tail, and framing subsystems and it is designed to be modular so that parts are easy to replace and require minimal maintenance. Primary materials used in construction were foam, carbon fiber, and aluminum. Testing of the frame yielded a weight of 8.63 kg, minimum foam strength of 1.70 MPa, and a minimum factor of safety of 16 for the structural members of the frame. Although the weight of the airframe is higher than the desired weight, this was necessary in order to satisfy the strength requirements and protect sensitive electrical components during initial flight tests. In the future, this extra weight could be decreased by using less carbon fiber, lower density foam, smaller, lighter material for the structural members, or smaller fasteners

Design and manufacturing workshop using the design thinking methodology

Comunicació presentada al ICERI 2019 12th annual International Conference of Education, Research and Innovation (Seville, Spain. 11-13 November, 2019).The purpose of this paper is to describe and discuss the experience under the methodology of Design Thinking, using a workshop format. This workshop, which took place on October 18th and 19th, 2018, in the BUC (Biblioteca Urbana del Coneixement) building in Vila-real, was attended by about a hundred students who had been displaced from the EASD in Valencia. The objective was to create an artistic work for the municipality of Vila-real with the students collaboration. Design Thinking methodology was implemented to carry out the artistic work. The ultimate goal was not only to get an idea, it was important to build it. The students were able to follow the manufacturing process in collaboration with the KrionTM company that offered their Solid Surface product, which possibilities in design terms this company is currently exploring. This was done in the following months, as the manufacture required its time

Energy-efficient through-life smart design, manufacturing and operation of ships in an industry 4.0 environment

Energy efficiency is an important factor in the marine industry to help reduce manufacturing and operational costs as well as the impact on the environment. In the face of global competition and cost-effectiveness, ship builders and operators today require a major overhaul in the entire ship design, manufacturing and operation process to achieve these goals. This paper highlights smart design, manufacturing and operation as the way forward in an industry 4.0 (i4) era from designing for better energy efficiency to more intelligent ships and smart operation through-life. The paper (i) draws parallels between ship design, manufacturing and operation processes, (ii) identifies key challenges facing such a temporal (lifecycle) as opposed to spatial (mass) products, (iii) proposes a closed-loop ship lifecycle framework and (iv) outlines potential future directions in smart design, manufacturing and operation of ships in an industry 4.0 value chain so as to achieve more energy-efficient vessels. Through computational intelligence and cyber-physical integration, we envision that industry 4.0 can revolutionise ship design, manufacturing and operations in a smart product through-life process in the near future

Design for Additive Manufacturing: A Method to Explore Unexplored Regions of the Design Space

Additive Manufacturing (AM) technologies enable the fabrication of parts and devices that are geometrically complex, have graded material compositions, and can be customized. To take advantage of these capabilities, it is important to assist designers in exploring unexplored regions of design spaces. We present a Design for Additive Manufacturing (DFAM) method that encompasses conceptual design, process selection, later design stages, and design for manufacturing. The method is based on the process-structure-property-behavior model that is common in the materials design literature. A prototype CAD system is presented that embodies the method. Manufacturable ELements (MELs) are proposed as an intermediate representation for supporting the manufacturing related aspects of the method. Examples of cellular materials are used to illustrate the DFAM method.Mechanical Engineerin

Generative feature-based design-by-constraints as a means of integration within the manufacturing industry

The article examines the development of computer aids within manufacturing industry and proposes an alternative approach to the way we design and the designer's role within manufacturing. A feature-based generative design-by-constraints approach is applied, which requires the designer to specify solutions in terms of manufacturing data, which is captured by means of an interactive simulation of machining processes, in which the constraints of equipment, materials and tools are displayed to the designer. The effect of this approach on the integration of all areas within a manufacturing environment is explored, as is the simultaneous design nature of this approach

An intelligent approach to design three-dimensional aircraft sheet metal part model for manufacture

Aircraft sheet metal part manufacturing is a knowledge-intensive process, and the manufacturability and manufacturing information are required to be considered in three-dimensional (3D) model by knowledge reuse. This paper presents a 3D model structure of the aircraft sheet metal part and an intelligent approach to design the model for manufacture combining intelligent manufacturability analysis with manufacturing information definition. Processability of part, formability of material and cost of fabrication are proposed to analyse the manufacturability of the part. Knowledge base for manufacturability analysis is established, and knowledge is reused to evaluate the part’s manufacturability intelligently to meet the constraints of manufacturing conditions. Non-geometric information is defined in the 3D model to meet the needs of digital manufacturing and inspection using model-based technology. An example is given to describe the process of design for manufacture, which shows that the approach can realize the concurrent design and digital manufacturing of aircraft sheet metal

Product design-Process selection-Process planning Integration based on Modelling and Simulation

As a solution for traditional design process having many drawbacks in the manufacturing process, the integration of Product design-Process selection-Process planning is carried out in the early design phase. The technological, economic, and logistic parameters are taken into account simultaneously as well as manufacturing constraints being integrated into the product design. As a consequence, the most feasible alternative with regard to the product’s detailed design is extracted satisfying the product’s functional requirements. Subsequently, a couple of conceptual process plans are proposed relied on manufacturing processes being preliminarily selected in the conceptual design phase. Virtual manufacturing is employed under CAM software to simulate fabrication process of the potential process plans. Ultimately, the most suitable process plan for fabricating the part is recommended based upon a multi-criteria analysis as a resolution for decision making

Redesign optimization for manufacturing using additive layer techniques

Improvements in additive manufacturing technologies have the potential to greatly provide value to designers that could also contribute towards improving the sustainability levels of products as well as the production of lightweight products. With these improvements, it is possible to eliminate the design restrictions previously faced by manufacturers. This study examines the principles of additive manufacturing, design guidelines, capabilities of the manufacturing processes and structural optimisation using topology optimisation. Furthermore, a redesign methodology is proposed and illustrated through a redesign case study of an existing bracket. The optimal design is selected using multi-criteria decision analysis method. The challenges for using additive manufacturing technologies are discussed

Deriving a systematic approach to changeable manufacturing system design

It has long been argued that Factories are long life and complex products. The complexity of designing factories, and their underlying manufacturing systems, is further amplified when dealing with continuously changing customer demands. At the same time, due to research fragmentation, little if any scientific explanations are available supporting and exploiting the paradigm that "factories are products". In order to address this weakness, this paper presents research results arising from a comparative analysis of systematic "product design" and "manufacturing system design" approaches. The contribution emerging from this research is an integrated systematic design approach to changeable manufacturing systems, based on scientific concepts founded upon product design theories, and is explained through a case study in the paper. This research is part of collaboration between the CERU University of Malta and IAO Fraunhofer aimed at developing a digital decision support tool for planning changeable manufacturing systems.peer-reviewe