A Framework to Collect and Reuse Engineering Knowledge in the Context of Design for Additive Manufacturing

Design for AM (DfAM) requires the definition of Design Actions (DAs) to optimize AM manufacturing processes. However, AM understanding is still very blurred. Often designers are challenged by selecting the right design parameters. A method to list and collect DfAM DAs is currently missing. The paper aims at providing a framework to collect DfAM DAs according to a developed ontology to create databases (DBs). DBs were tested with two real case studies and geometric features to improve identified. Future developments aim at widening the database to provide all-around support for AM processes

Cost Sensitivity Analysis for Laser Powder Bed Fusion

Laser Powder Bed Fusion is the most widespread additive manufacturing process for metals. In literature, there are several analytical models for estimating the manufacturing cost. However, few papers present sensitivity analyses for evaluating the most relevant product and process parameters on the production cost. This paper presents a cost model elaborated from previous studies used in a sensitivity analysis. The most relevant process parameters observed in the sensitivity analysis are the 3D printer load factor, layer thickness, raw material price and laser speed

An eco-knowledge tool to support eco-design implementation inside design departments

In last years, an increasing attention on environmental matters is registered. Companies face environmental matters to increase the environmental performances of their products, forced by numerous legislations, normative and protocols and induced to the growing attention of consumers toward environmentally friendly products. However, observing the industrial context, it emerges there are several barriers for implementation of eco-design strategies inside design departments. The paper presents a tool which aims at both providing a basic guide on environmental sustainability issues and favouring the knowledge sharing among the different actors of the product design process. The core of the tool is a repository in which company materials, organized and collected in different forms, are collected. The repository contains several parts: training, guidelines, knowledge and milestone, accordingly to the type, structure and form of materials stored. The eco-design tool functions, structure, and workflow are presented and then preliminary test cases are described

An analytical cost estimation approach for generic sheet metal 3D models

This paper defines a systematic workflow for production cost estimation of sheet metal stamped components. The approach represents a solution toward the adoption of Design to Cost methods during early product design. It consists in a sequence of steps that, starting from a 3D CAD model with annotations (material, roughness and tolerances) and production information (batch and production volume) leads to the manufacturing cost through an analytic cost breakdown (raw material, stamping and accessory processes, setup and tooling). The calculation process mainly consists in a first step where geometric algorithms calculate the sheet metal blank (dimensions, shape, thickness) and specific product features (e.g. flanges, louvers, embossing, etc.). The following steps allow to calculate the raw material, the stamping process and the process-related parameters, which are the manufacturing cost drivers (e.g. press, stamping rate/sequence/force and die dimensions/weight). The manufacturing cost is the sum of the previous calculated items. Testing the approach for three different components, the average absolute deviation measured between the estimated and actual cost was less than 10% and such a result looks promising for adopting this method for evaluating alternative design solutions

Parametric cost modelling of components for turbomachines: Preliminary study

The ever-increasing competitiveness, due to the market globalisation, has forced the industries to modify their design and production strategies. Hence, it is crucial to estimate and optimise costs as early as possible since any following changes will negatively impact the redesign effort and lead time. This paper aims to compare different parametric cost estimation methods that can be used for analysing mechanical components. The current work presents a cost estimation methodology which uses non-historical data for the database population. The database is settled using should cost data obtained from analytical cost models implemented in a cost estimation software. Then, the paper compares different parametric cost modelling techniques (artificial neural networks, deep learning, random forest and linear regression) to define the best one for industrial components. Such methods have been tested on 9 axial compressor discs, different in dimensions. Then, by considering other materials and batch sizes, it was possible to reach a training dataset of 90 records. From the analysis carried out in this work, it is possible to conclude that the machine learning techniques are a valid alternative to the traditional linear regression ones

Environmental implication of personal protection equipment in the pandemic era: LCA comparison of face masks typologies

In the present global health emergency, face masks play a key role in limiting the diffusion of the COVID-19 pandemic, by acting as physical barriers to avoid droplets and filtrate exhalations coming from infected subjects. Since the most widespread devices are disposable products made of plastic materials, this means that relevant quantities of fossil resources will be consumed, and huge amounts of wastes will be generated. The present paper aims to compare the environmental performances of five different typologies of face masks (i.e. 3D printed reusable mask with filter, surgical mask, filtering face-piece masks-FFPs with and without valve, washable masks), considering an average Italian use scenario and the whole mask lifecycle: materials, manufacturing processes, use, sanitization, and disposal. The Life Cycle Assessment methodology has been used to assess the environmental impacts in terms of both ReCiPe midpoints and endpoints. Reusable masks and masks with interchangeable filters could potentially contribute to improve the environmental performances in all the considered impact and damage categories. Eco-design actions can be developed starting from the study results

Challenging the engineering design process for the development of facial masks in the constraint of the COVID-19 pandemic

The most effective ways to mitigate the diffusion of the COVID-19 pandemic are social distancing and the use of face masks as barrier to avoid droplets and to filtrate exhalations coming from infected subjects. Currently used face masks are products developed to be used by workers, both in health care and other contexts, where their use is limited in time and the disposal scenario is properly managed. Their use in a pandemic situation can be thus considered a remedial action due to the emergency. New masks or mask families are needed based on the desirable requirements retrieved by the analysis of the current worldwide situation and covering the gap observed in the market. The present paper aims to describe the complete product development process of a new facial mask (or mask family) for a daily use on a pandemic situation. It challenges the time constraint of the COVID-19 pandemic by adopting a four-step approach and concurrent development of the first phases (definition of requirements and functional derivation). The engineering design process allows to derive two different solutions able to fulfil all the requirements (demands and wishes) of final users, by assuring high ergonomic performance, as well as environmental, economic, and social sustainability

Eco-design actions to improve life cycle environmental performance of face masks in the pandemic era

Face masks are currently considered essential devices that people must wear today and in the near future, until the COVID-19 pandemic will be completely defeated through specific medicines and vaccines. Such devices are generally made of thermoplastic polymers, as polypropylene and polyethylene and are single use products. Even if in this period the sanitary emergency must have the maximum priority, the world society should not completely forget the environmental problem that are causing more and more obvious climate changes with correlated damages to ecosystems and human health. Despite the well-known correlation among anti-COVID protective equipment (or more generally medical devices) and environmental issues, the Life Cycle Assessment (LCA) and eco-design-based studies in this field is very scarce. The present study aims to derive the most important environmental criticalities of such products, by using LCA and product circularity indicators of five different common masks. The final aim is to provide eco-design guidelines, useful to design new face masks by preventing negative impact on the environment

Hypothermic Machine Perfusion in Kidney Transplantation: Back to the Future?

Static cold storage is currently the most used method of organ preservation worldwide. However, cutting edge technology and dramatic changes in the donor pattern have lately renewed the interest toward hypothermic machine perfusion. Marginal and cardiac death donors show higher rates of primary non function and delayed graft function compared to standard criteria donors. In this setting, machine perfusion may offer several theoretical advantages such as improved organ preservation, continuous graft evaluation, and ex-vivo conditioning of the graft before implantation. These topics have been recently reassessed by several studies. In particular, perfusion characteristics (renal resistance) and perfusate biomarker concentrations (lactate dehydrogenase, aspartate aminotransferase, heart-type fatty acid binding protein, and IL-18) during machine preservation, proved to be reliable tools to rule out graft viability and predict outcomes after transplantation. Treatment strategies acting on tissue repair, cell metabolism, and allorecognition pathway are also under investigation with promising results. Machine perfusion has finally shown its real potential however, stronger evidences and updated cost-effectiveness analysis are needed to fully support its role for the next future

Treatment options for localised renal cell carcinoma of the transplanted kidney

Currently, there is no consensus among the transplant community about the treatment of renal cell carcinoma (RCC) of the transplanted kidney. Until recently, graftectomy was universally considered the golden standard, regardless of the characteristics of the neoplasm. Due to the encouraging results observed in native kidneys, conservative options such as nephron-sparing surgery (NSS) (enucleation and partial nephrectomy) and ablative therapy (radiofrequency ablation, cryoablation, microwave ablation, high-intensity focused ultrasound, and irreversible electroporation) have been progressively used in carefully selected recipients with early-stage allograft RCC. Available reports show excellent patient survival, optimal oncological outcome, and preserved renal function with acceptable complication rates. Nevertheless, the rarity and the heterogeneity of the disease, the number of options available, and the lack of long-term follow-up data do not allow to adequately define treatment-specific advantages and limitations. The role of active surveillance and immunosuppression management remain also debated. In order to offer a better insight into this difficult topic and to help clinicians choose the best therapy for their patients, we performed and extensive review of the literature. We focused on epidemiology, clinical presentation, diagnostic work up, staging strategies, tumour characteristics, treatment modalities, and follow-up protocols. Our research confirms that both NSS and focal ablation represent a valuable alternative to graftectomy for kidney transplant recipients with American Joint Committee on Cancer stage T1aN0M0 RCC. Data on T1bN0M0 lesions are scarce but suggest extra caution. Properly designed multi-centre prospective clinical trials are warranted