Design Strategies for the Process of Additive Manufacturing

Additive manufacturing (AM) is a cyclic manufacturing process to create three-dimensional objects layer-by-layer directly from a 3D CAD model. Today AM processes like SLM and SLS are already suitable for direct part production. The processes have little restrictions regarding the shape of the object. The challenge to a designer is to use the unique characteristics of additive manufacturing in the development process to create an added value for the manufacturer and the user of a product. This paper presents two design strategies to use additive manufacturing\u27s benefits in product development. A manufacturing driven design strategy allows a substitution of manufacturing processes at a later stage of the product life cycle, while a function driven design strategy increases the performance of a product. The choice of strategy has great impact on the development process and the design of components. Two cases are presented to explain and illustrate these design strategies

Considering Part Orientation in Design for Additive Manufacturing

Additive Manufacturing (AM) is established not only in prototyping, but also in serial production of end-use products. To use the full potential of the production technology the restrictions of current additive manufacturing processes (like support structures in Selective Laser Melting) must be considered in the design process. Especially the compliance with design rules from early design stages on is important in AM serial production, due to production quantities and the resulting scale effect. The part orientation in the build space has a strong influence on many quality characteristics. In order to use the full potential and to consider the restrictions from the start, a design guideline is necessary to support the whole design process. For this purpose, this paper presents a framework for design guidelines. The framework distinguishes between process characteristics, design principles and design rules; each supporting the designer during different stages of the design process. Furthermore, the paper examines the influence of part orientation in existing design rules and elaborates its importance. Based on this result, the design principle “early determination of part orientation” is presented, which includes a process for determining the part orientation in early stage of the design process. In addition, a design process for additive manufactured parts is demonstrated on an extensive showcase, following the guideline framework and including the principle for early determination of part orientation. The presented framework proved to be helpful in the design process and will be used in the future to collect more process characteristics, design principles and rules

Composites Part Production with Additive Manufacturing Technologies

Additive Manufacturing (AM) is of particular interest in the context of composite part production as AM promises the production of integrated, complex structures with low lead times. Currently, AM is used for tooling and sandwich cores with added functionalities. This paper presents four design principles that improve the production of composites parts during layup, handling, curing and post processing in the layup process. Design principles are applied to a hat-stiffener, a highly integrated aircraft instrument panel and a novel insert eliminating drilling operations. Results show that AM can reduce the part count, assembly steps and deformations during curing

Die Entwicklung des Non-Aviation-Bereichs und seine Bedeutung für die europäischen Flughäfen

Durch verschiedene Entwicklungen in der Luftverkehrsbranche können sich die Flughäfenheutzutage nicht mehr auf ihre ehemalige Haupteinnahmequelle, den Flugbetrieb, verlassen.Zudem wird vor dem Hintergrund steigender Passagierzahlen ein hoher Kapitalaufwand fürden Ausbau der Kapazitäten benötigt.Die Flughäfen müssen daher mehr Wertschöpfung aus einem anderen Geschäftsfeldgenerieren. Der Non-Aviation-Bereich, der sich nicht direkt auf den Flugbetrieb bezieht,rückte in den Fokus der Flughäfen. Aus den Verkehrsknotenpunkten Flughäfen werden mehrund mehr multifunktionale Airport Cities mit Geschäftszentren, Dienstleistungs-,Einzelhandels- und Gastronomieangeboten.Ziel der Arbeit ist es, die Entwicklung des Non-Aviation-Bereichs in den letzten 20 Jahrendarzustellen. Vor allem die Veränderungen in den Bereichen Retail und Immobilien werdendabei näher betrachtet. Abschließend werden Non-Aviation-Kennzahlen ausgewähltereuropäischer Flughäfen miteinander verglichen und Beispiele des Non-Aviation-Segmentsanhand verschiedener Flughäfen aufgezeigt

Additive Fertigung in der industriellen Serienproduktion: Bauteilidentifikation und Gestaltung

Additive Manufacturing (AM), often referred to as 3D printing, is developing very dynamically. The technology and its machines are so mature that additive series production of final components is possible. The digital process chain and in particular the freedom of design are the outstanding properties of the process. If these advantages are properly exploited, serial components can be produced economically - despite the still high manufacturing costs - which has already been proven by various applications. However, despite their high potential, the processes are by no means widely established in series production and are only hesitantly adopted by companies. The lack of know-how and expertise in dealing with the technology is named as a major obstacle by the industry. This applies mainly to the identification of suitable components and their production-specific design. In order to determine the reasons for the lack of expertise despite the provision of knowledge, a literature-based analysis of the reasons is carried out. On this basis, tools and transfer methods are developed to support the implementation of additive series production. An orientation scheme based on potential clusters provides assistance in identification, enabling manual identification. In addition, a documentation and evaluation system is provided which ensures efficient cooperation with AM experts and the formation of identification expertise in the company. Design is a key issue for AM, as it requires a radical rethink in comparison to conventional design, so that the full potential of the technology can be exploited. In order to offer a support suitable for the target group, design guideline is being developed consisting of the three elements: process characteristics, design principles and guideline values. The technology transfer and the transfer of the AM tools - with corresponding experience in their handling - is the prerequisite for the formation of AM expertise in the companies. The Experience-based Transfer Model (ETM) is developed for this purpose, taking into account the findings from the literature analysis. The implementation in the transfer projects shows that the developed support tools for identification and design are successfully applied in industrial applications. The ETM promotes an effective AM expertise formation in the company and supports the acceptance of the provided tools, since their suitability for use is experienced directly on the own product. The combination of support tools and transfer methods enables the implementation of additive manufacturing in series production and facilitates access to technology for companies

Topographic relations between ocular dominance and orientation columns in the cat striate cortex

Löwel S, Bischof H-J, Leutenecker B, Singer W. Topographic relations between ocular dominance and orientation columns in the cat striate cortex. Experimental Brain Research. 1988;71(1):33-46.In the visual cortex of four adult cats ocular dominance and orientation columns were visualized with (3H)proline and (14C)deoxyglucose autoradiography. The two columnar systems were reconstructed from serial horizontal sections or from flat-mount preparations and graphically superimposed. They share a number of characteristic features: In both systems the columns have a tendency to form regularly spaced parallel bands whose main trajectory is perpendicular to the border between areas 17 and 18. These bands frequently bifurcate or terminate in blind endings. The resulting irregularities are much more pronounced in the ocular dominance than in the orientation system. The periodicity of the columnar patterns was assessed along trajectories perpendicular to the main orientation of the bands and differed in the two columnar systems. The spacing of the ocular dominance stripes was significantly narrower than the spacing of orientation bands. The mean periodicity of a particular columnar system was virtually identical in the two hemispheres of the same animal but it differed substantially in different animals. However, the spacing of orientation columns covaried with that of the ocular dominance columns, the ratios of the mean spacings of the two columnar systems being similar in the four cats. The superposition of the two columnar systems revealed no obvious topographic relation between any of the organizational details such as the location of bifurcations, blind endings and intersections. We suggest the following conclusions: 1. The developmental processes generating the two columnar systems seem to obey the same algorithms but they act independently of each other. 2. The space constants of the two systems are rigorously specified and appear to depend on a common variable. 3. The main orientation of the bands in both columnar systems is related to a) the representation of the vertical meridian, b) the anisotropy of the cortical magnification factor, and c) the tangential spread of intracortical connections

Design Strategies for the Process of Additive Manufacturing

Additive manufacturing (AM) is a cyclic manufacturing process to create three-dimensional objects layer-by-layer directly from a 3D CAD model. Today AM processes like SLM and SLS are already suitable for direct part production. The processes have little restrictions regarding the shape of the object. The challenge to a designer is to use the unique characteristics of additive manufacturing in the development process to create an added value for the manufacturer and the user of a product. This paper presents two design strategies to use additive manufacturing's benefits in product development. A manufacturing driven design strategy allows a substitution of manufacturing processes at a later stage of the product life cycle, while a function driven design strategy increases the performance of a product. The choice of strategy has great impact on the development process and the design of components. Two cases are presented to explain and illustrate these design strategies.ISSN:2212-827

Considering Part Orientation in Design for Additive Manufacturing

Additive Manufacturing (AM) is established not only in prototyping, but also in serial production of end-use products. To use the full potential of the production technology the restrictions of current additive manufacturing processes (like support structures in Selective Laser Melting) must be considered in the design process. Especially the compliance with design rules from early design stages on is important in AM serial production, due to production quantities and the resulting scale effect. The part orientation in the build space has a strong influence on many quality characteristics. In order to use the full potential and to consider the restrictions from the start, a design guideline is necessary to support the whole design process. For this purpose, this paper presents a framework for design guidelines. The framework distinguishes between process characteristics, design principles and design rules; each supporting the designer during different stages of the design process. Furthermore, the paper examines the influence of part orientation in existing design rules and elaborates its importance. Based on this result, the design principle “early determination of part orientation” is presented, which includes a process for determining the part orientation in early stage of the design process. In addition, a design process for additive manufactured parts is demonstrated on an extensive showcase, following the guideline framework and including the principle for early determination of part orientation. The presented framework proved to be helpful in the design process and will be used in the future to collect more process characteristics, design principles and rules.ISSN:2212-827