A Design Framework for Additive Manufacturing: Integration of Additive Manufacturing Capabilities in the Early Design Process

Sarath C. Renjith,Kijung Park,Gül E. Okudan Kremer 한국정밀공학회 2020 International Journal of Precision Engineering and Vol.21 No.2

Additive manufacturing has emerged as an integral part of modern manufacturing because of its unique capabilities in various application domains. As efforts to effectively apply additive manufacturing, design for additive manufacturing (DfAM) has risen to provide a set of guidelines based on a practical design framework or a methodology during the product design process of additive manufacturing. However, most existing DfAM methods do not effectively consider the capabilities of extant additive manufacturing technologies in the early design stages, and therefore it is hard to map functional requirements from customer needs onto a product design for additive manufacturing. Moreover, available DfAM methods tend to rely on the direct application of a specific decision method rather than a systematic approach with appropriate deployment and transformation of available design decision methods considering the additive manufacturing environment. Consequently, existing DfAM methods lack suitability for use by additive manufacturing novices. To tackle these issues, this study develops a design framework for additive manufacturing through the integration of axiomatic design and theory of inventive problem-solving (TRIZ). This integrated approach is effective because the axiomatic design approach can be used to systematically define and analyze a design problem, while the TRIZ problem-solving approach combined with an additive manufacturing database can be used as an idea generation tool to generate innovative solutions for the design problem. A case study for a housing cover redesign is presented to apply and validate the proposed design framework.

Additive manufacturing (AM) of piercing punches by the PBF method of metal 3D printing using mold steel powder materials

Rui Li,김용석,Hoang Van Tho,염영진,김원준,양순용 대한기계학회 2019 JOURNAL OF MECHANICAL SCIENCE AND TECHNOLOGY Vol.33 No.2

The purpose of this study is to develop additive manufacturing fabrication for high-strength punches. After screening the powder material and the manufacturing method, a solution possessing excellent mechanical properties was selected for manufacturing. Additive manufacturing specimens and comparative specimens were fabricated using metal materials while the comparative specimens were produced with bulk materials in the same grade as the powder materials. The specimens were tested to determine their mechanical properties. The additive manufacturing specimens were produced through the PBF method for three kinds of die steel powder materials: H13, M300 and KP4. In the experimental section, tests for density, hardness, and toughness were included. SEM and EDS analysis were also used in this study to analyze and observe the microstructure of the additive manufacturing specimens. Considering the mechanical properties test and the SEM and EDS results, it was easy to determine that M300 was the most suitable material for high-strength punches. It not only possesses better mechanical properties, but also a better microstructure than the other two materials. The punch fabricated by the M300 and PBF additive manufacturing methods exhibited good performance in durability testing. In this study, the use of 3D printing technology to produce high-strength punches with high-strength die steel powder material has become a reality. In the future, the process parameters should be optimized and post-processing of punches should be added to obtain additive-manufacturing punches with better mechanical properties.

Lasers in Additive Manufacturing: A Review

이협,김영진,Chin Huat Joel Lim,Mun Ji Low,Nicholas Tham,Vadakke Matham Murukeshan 한국정밀공학회 2017 International Journal of Precision Engineering and Vol.4 No.3

In recent years, additive manufacturing, also known as three-dimensional (3D) printing, has emerged as an environmentally friendly green manufacturing technology which brings great benefits, such as energy saving, less material consumption, and efficient production. These advantages are attributed to the successive material deposition at designated target areas by delivering the energy on it. In this regard, lasers are the most effective energy source in additive manufacturing since the laser beam can transfer a large amount of energy into micro-scale focal region instantaneously to solidify or cure materials in air, therefore enabling high-precision and high-throughput manufacturing for a wide range of materials. In this paper, we introduce laser-based additive manufacturing methods and review the types of lasers widely used in 3D printing machines. Important laser parameters relevant to additive manufacturing will be analyzed and general guidelines for selecting suitable lasers for additive manufacturing will be provided. Discussion on future prospects of laser technologies for additive manufacturing will be finally covered.

An additive manufacturing oriented design approach to mechanical assemblies

Germain Sossou,Frédéric Demoly,Ghislain Montavon,Samuel Gomes 한국CDE학회 2018 Journal of computational design and engineering Vol.5 No.1

Firstly introduced as a prototyping process, additive manufacturing (AM) is being more and more considered as a fully-edged manufacturing process. The number of AM processes, along with the range of processed materials are expanding. AM has made manufacturable shapes that were too difficult (or even impossible) to manufacture with conventional technologies. This has promoted a shift in engineering design, from conventional design for manufacturing and assembly to design for additive manufacturing (DFAM). Research efforts into the DFAM field have been mostly dedicated to part’s design, which is actually a requirement for a better industrial adoption. This has given rise to topologically optimized and/or latticed designs. However, since AM is also capable of manufacturing fully functional assemblies requiring a few or no assembly operations, there is a need for DFAM methodologies tackling product’s development more holistically, and which are, therefore, dedicated to assembly design. Considering all the manufacturing issues related to AM of assembly-free mechanisms and available post-processing capabilities, this paper proposes a top-down assembly design methodology for AM in a proactive manner. Such an approach, can be seen as the beginning of a shift from conventional design for assembly (DFA) to a new paradigm. From a product’s concept and a selected AM technology, the approach first provides assistance in the definition of the product architecture so that both functionality and successful manufacturing (including post-processing) are ensured. Particularly, build-orientation and downstream processes’ characteristics are taken into account early in the design process. Secondly, for the functional flow (energy, material, signal) to be appropriately conveyed by the right amount of matter, the methodology provides guidance into how the components can be designed in a minimalism fashion leveraging the shape complexity afforded by AM. A mechanical assembly as case study is presented to illustrate the DFAM methodology. It is found that clearances and material (be it raw unprocessed material or support structures) within them plays a pivotal role in a successful assembly’s design to be additively manufactured. In addition, the methodology for components’ design proves to be an efficient alternative to topology optimization. Though, the approach can be extended by considering a strategy for part consolidation and the possibility to manufacture the assemblies with more than one AM process. As regards components’ design, considering anisotropy can also improved the approach.

An additive manufacturing oriented design approach to mechanical assemblies

Sossou, Germain,Demoly, Frederic,Montavon, Ghislain,Gomes, Samuel Society for Computational Design and Engineering 2018 Journal of computational design and engineering Vol.5 No.1

Firstly introduced as a prototyping process, additive manufacturing (AM) is being more and more considered as a fully-edged manufacturing process. The number of AM processes, along with the range of processed materials are expanding. AM has made manufacturable shapes that were too difficult (or even impossible) to manufacture with conventional technologies. This has promoted a shift in engineering design, from conventional design for manufacturing and assembly to design for additive manufacturing (DFAM). Research efforts into the DFAM field have been mostly dedicated to part's design, which is actually a requirement for a better industrial adoption. This has given rise to topologically optimized and/or latticed designs. However, since AM is also capable of manufacturing fully functional assemblies requiring a few or no assembly operations, there is a need for DFAM methodologies tackling product's development more holistically, and which are, therefore, dedicated to assembly design. Considering all the manufacturing issues related to AM of assembly-free mechanisms and available post-processing capabilities, this paper proposes a top-down assembly design methodology for AM in a proactive manner. Such an approach, can be seen as the beginning of a shift from conventional design for assembly (DFA) to a new paradigm. From a product's concept and a selected AM technology, the approach first provides assistance in the definition of the product architecture so that both functionality and successful manufacturing (including post-processing) are ensured. Particularly, build-orientation and downstream processes' characteristics are taken into account early in the design process. Secondly, for the functional flow (energy, material, signal) to be appropriately conveyed by the right amount of matter, the methodology provides guidance into how the components can be designed in a minimalism fashion leveraging the shape complexity afforded by AM. A mechanical assembly as case study is presented to illustrate the DFAM methodology. It is found that clearances and material (be it raw unprocessed material or support structures) within them plays a pivotal role in a successful assembly's design to be additively manufactured. In addition, the methodology for components' design proves to be an efficient alternative to topology optimization. Though, the approach can be extended by considering a strategy for part consolidation and the possibility to manufacture the assemblies with more than one AM process. As regards components' design, considering anisotropy can also improved the approach.

Energy Consumption Model for Additive-Subtractive Manufacturing Processes with Case Study

Marcus A. Jackson,Arik Van Asten,Justin D. Morrow,Sangkee Min,Frank E. Pfefferkorn 한국정밀공학회 2018 International Journal of Precision Engineering and Vol.5 No.4

There has been a growing trend in industry towards the development of integrated manufacturing centers that combine several manufacturing processes, such as the mill-turn center. As additive manufacturing becomes a more widely adopted technology, combining additive with subtractive manufacturing in one machine is a logical evolution to provide the benefits of final parts made from raw materials with the dimensional tolerance and surface finish expected in many applications. An energy consumption model was created that accounted for the energy consumption during primary metal production, deposition, and machining phases of wire-based and powder-based additive-subtractive manufacturing processes. This model was applied to a case study where the energy consumption to produce sub-sized, sheet type, and plate type (size) tensile bars was calculated. It was found that the wire-based process consumed less energy during deposition, whereas powder-based was less energy consumptive during primary metal production and machining. The findings suggest that given the present understanding of the respective technologies’ capabilities, the desired final net shape will dictate the preferred manufacturing process with respect to energy consumption considerations.

Comparison of prosthetic models produced by traditional and additive manufacturing methods

Jin-Young Park,Hae-Young Kim,Ji-Hwan Kim,Jae-Hong Kim,Woong-Chul Kim 대한치과보철학회 2015 The Journal of Advanced Prosthodontics Vol.7 No.4

PURPOSE The purpose of this study was to verify the clinical-feasibility of additive manufacturing by comparing the accuracy of four different manufacturing methods for metal coping: the conventional lost wax technique (CLWT); subtractive methods with wax blank milling (WBM); and two additive methods, multi jet modeling (MJM), and micro-stereolithography (Micro-SLA). MATERIALS AND METHODS Thirty study models were created using an acrylic model with the maxillary upper right canine, first premolar, and first molar teeth. Based on the scan files from a non-contact blue light scanner (Identica; Medit Co. Ltd., Seoul, Korea), thirty cores were produced using the WBM, MJM, and Micro-SLA methods, respectively, and another thirty frameworks were produced using the CLWT method. To measure the marginal and internal gap, the silicone replica method was adopted, and the silicone images obtained were evaluated using a digital microscope (KH-7700; Hirox, Tokyo, Japan) at 140X magnification. Analyses were performed using two-way analysis of variance (ANOVA) and Tukey post hoc test (α=.05). RESULTS The mean marginal gaps and internal gaps showed significant differences according to tooth type (P<.001 and P<.001, respectively) and manufacturing method (P<.037 and P<.001, respectively). Micro-SLA did not show any significant difference from CLWT regarding mean marginal gap compared to the WBM and MJM methods. CONCLUSION The mean values of gaps resulting from the four different manufacturing methods were within a clinically allowable range, and, thus, the clinical use of additive manufacturing methods is acceptable as an alternative to the traditional lost wax-technique and subtractive manufacturing.

Comparison of prosthetic models produced by traditional and additive manufacturing methods

박진영,김혜영,김지환,김재홍,김웅철 대한치과보철학회 2015 The Journal of Advanced Prosthodontics Vol.7 No.4

PURPOSE. The purpose of this study was to verify the clinical-feasibility of additive manufacturing by comparing the accuracy of four different manufacturing methods for metal coping: the conventional lost wax technique (CLWT); subtractive methods with wax blank milling (WBM); and two additive methods, multi jet modeling (MJM), and micro-stereolithography (Micro-SLA). MATERIALS AND METHODS. Thirty study models were created using an acrylic model with the maxillary upper right canine, first premolar, and first molar teeth. Based on the scan files from a non-contact blue light scanner (Identica; Medit Co. Ltd., Seoul, Korea), thirty cores were produced using the WBM, MJM, and Micro-SLA methods, respectively, and another thirty frameworks were produced using the CLWT method. To measure the marginal and internal gap, the silicone replica method was adopted, and the silicone images obtained were evaluated using a digital microscope (KH-7700; Hirox, Tokyo, Japan) at 140X magnification. Analyses were performed using two-way analysis of variance (ANOVA) and Tukey post hoc test (α=.05). RESULTS. The mean marginal gaps and internal gaps showed significant differences according to tooth type (P<.001 and P<.001, respectively) and manufacturing method (P<.037 and P<.001, respectively). Micro-SLA did not show any significant difference from CLWT regarding mean marginal gap compared to the WBM and MJM methods. CONCLUSION. The mean values of gaps resulting from the four different manufacturing methods were within a clinically allowable range, and, thus, the clinical use of additive manufacturing methods is acceptable as an alternative to the traditional lost wax-technique and subtractive manufacturing.

Comparison of prosthetic models produced by traditional and additive manufacturing methods

Park, Jin-Young,Kim, Hae-Young,Kim, Ji-Hwan,Kim, Jae-Hong,Kim, Woong-Chul The Korean Academy of Prosthodonitics 2015 The Journal of Advanced Prosthodontics Vol.7 No.4

PURPOSE. The purpose of this study was to verify the clinical-feasibility of additive manufacturing by comparing the accuracy of four different manufacturing methods for metal coping: the conventional lost wax technique (CLWT); subtractive methods with wax blank milling (WBM); and two additive methods, multi jet modeling (MJM), and micro-stereolithography (Micro-SLA). MATERIALS AND METHODS. Thirty study models were created using an acrylic model with the maxillary upper right canine, first premolar, and first molar teeth. Based on the scan files from a non-contact blue light scanner (Identica; Medit Co. Ltd., Seoul, Korea), thirty cores were produced using the WBM, MJM, and Micro-SLA methods, respectively, and another thirty frameworks were produced using the CLWT method. To measure the marginal and internal gap, the silicone replica method was adopted, and the silicone images obtained were evaluated using a digital microscope (KH-7700; Hirox, Tokyo, Japan) at 140X magnification. Analyses were performed using two-way analysis of variance (ANOVA) and Tukey post hoc test (${\alpha}=.05$). RESULTS. The mean marginal gaps and internal gaps showed significant differences according to tooth type (P<.001 and P<.001, respectively) and manufacturing method (P<.037 and P<.001, respectively). Micro-SLA did not show any significant difference from CLWT regarding mean marginal gap compared to the WBM and MJM methods. CONCLUSION. The mean values of gaps resulting from the four different manufacturing methods were within a clinically allowable range, and, thus, the clinical use of additive manufacturing methods is acceptable as an alternative to the traditional lost wax-technique and subtractive manufacturing.

빅데이터 기반 적층제조 분석 플랫폼

허태상,정대용,김남규,황규현,김명일,서동우 한국정보통신학회 2023 한국정보통신학회논문지 Vol.27 No.8

Additive manufacturing is widely used in a variety of industries and is growing rapidly, but there are also technical challenges to be addressed, including production speed, material selection, product size limitations, precision and overall product quality. In addition, real-time data-based process monitoring, diagnosis, control, evaluation, and prediction technologies are desperately needed to develop these industries, and since manufacturing processes are expected to generate vast amounts of data in various forms, advanced analytics using operational data is essential demanded. In this study, we examine the domestic and international manufacturing status and government policy direction, and consider the big data platform and core technologies for additive manufacturing. In particular, by using big data generated during the additive manufacturing process and analysis process, product design improvement, product quality control, preemptive maintenance, efficient process support, and manufacturing environment optimization are aimed at improving reliability and efficiency. We will discuss the design and implementation of an additive manufacturing analytics platform. 적층제조는 다양한 산업에서 광범위하게 활용되며 급속히 성장하고 있지만, 생산 속도, 소재 선택, 제품 크기 제한, 정밀도 및 전반적인 제품품질을 포함한 해결해야 할 기술적 과제도 있다. 또한, 이런 산업을 발전시키기 위해서 실시간 데이터 기반 공정 모니터링, 진단, 제어, 평가 및 예측기술이 절실히 필요하며, 제조 프로세스는 다양한 형태의 많은 양의 데이터를 생성할 것으로 예상하므로 운영 데이터를 활용하는 고급 분석이 요구된다. 본 연구에서는 국내외 제조 현황과 정부 정책 방향을 살펴보고, 적층제조를 위한 빅데이터 플랫폼과 핵심기술을 고려한다. 특히 적층제조 공정 및 분석과정에서 발생하는 빅데이터를 활용하여 제품의 설계향상, 제품의 품질관리, 선제적 유지보수, 효율적인 프로세스 지원, 제조환경 최적화를 통해 신뢰성과 효율성 향상을 목표로 빅데이터 기반의 적층제조 분석 플랫폼의 설계 및 구현에 대해 논의하고자 한다.