design for additive manufacturing: tools and methods
TRANSCRIPT
General Assembly 2015, CapeTown, South Africa Dn 2016: Design for Additive ManufacturingCIRP2016WinterMeeting
STCDn 2020Keynoteproposal
DesignforAdditiveManufacturing:ToolsandMethods
ARemixofthe2016Team+OthersIncludingCMAG
2016Team:MaryKathrynThompson,GiovanniMoroni (2),TomVaneker (2),GeorgesFadel,R.IanCampbell, IanGibson,AlainBernard(1),JoachimSchulz(3),PatriciaGraf,Bhrigu Ahuja, Filomeno
Martina
General Assembly 2015, CapeTown, South Africa Dn 2016: Design for Additive ManufacturingCIRP2016WinterMeeting
Audience and Aim
2016keynotewasintendedtosupportindustryastheydecideif,when,andwhytodesignpartsandproductsthatwillbeproducedwithadditivemanufacturingtechnology.- Highestleveloverview- Aimedatdecisionmakers- Verystrategic
2020keynoteisintendedtosupportindustryaftertheyhavedecidedtodesignforAMastheyplanhowtoproceed.- Higherleveloverview (butlowerlevelthan2016)- Aimedatdesigners (technicalleads)- Morepractical(stilldesignfocused,notprocesstechnologyfocused)
General Assembly 2015, CapeTown, South Africa Dn 2016: Design for Additive ManufacturingCIRP2016WinterMeeting
Motivation
1.The2016keynotedoesnotfullyaddresstheimmediateneedsofindustry(CMAG)forsupportwithDfAM andcannotdosobecauseoftimeandspacelimitations.Theteamiswillingandabletofinishwhatwestarted.
2.Thereisawealthofinformationthathasalreadybeengathered,processed,organized,andanalyzedfromthe2016keynotethatcanserveastheinitialfoundationofthiswork.
General Assembly 2015, CapeTown, South Africa Dn 2016: Design for Additive ManufacturingCIRP2016WinterMeeting
Material Collected
- Over500academicreferences- Almost650manufacturer’s casestudies- Approximately40manufacturer’sdesignguides- PluscasestudiesandcontributionsfromCMAGmembers
Inaddition,weknowtherearemanypapersinthepipelinefromCIRPmembersthatwillbeaveryvaluablepartofthiscollection.
General Assembly 2015, CapeTown, South Africa Dn 2016: Design for Additive ManufacturingCIRP2016WinterMeeting
DesignforAdditiveManufacturing: Tools&Methods
StructuringthedesignprocessDesigndeliverables, documentation&tolerancing
(~14refs)
AdaptedPahl andBeits modelforAM(Goutier,Uni.Twente)
Blackbox modelforAMpartredesign(Lindeman)
General Assembly 2015, CapeTown, South Africa Dn 2016: Design for Additive ManufacturingCIRP2016WinterMeeting
DesignforAdditiveManufacturing: Tools&Methods
“Bottomup”functionalsurfaceapproachtodesign(5refs+2casestudies)
General Assembly 2015, CapeTown, South Africa Dn 2016: Design for Additive ManufacturingCIRP2016WinterMeeting
DesignforAdditiveManufacturing: Tools&Methods
TwoexcellentcasestudiesfromASML
General Assembly 2015, CapeTown, South Africa Dn 2016: Design for Additive ManufacturingCIRP2016WinterMeeting
3Dmodelgenerationmethods&tools
GenerativeDesign– latticestructurecreatedwithAutodeskWithin TopOpt Gripper(Langelaar,TUDelft)
DesignforAdditiveManufacturing: Tools&Methods
General Assembly 2015, CapeTown, South Africa Dn 2016: Design for Additive ManufacturingCIRP2016WinterMeeting
3Dmodelgenerationmethods&tools
TopOpt Variants(Lindeman)
DesignforAdditiveManufacturing: Tools&Methods
General Assembly 2015, CapeTown, South Africa Dn 2016: Design for Additive ManufacturingCIRP2016WinterMeeting
Modelsandtoolsfortopologyoptimizationandthecontrolofsupportstructuresandinfill
(19refs)
TopOpt withadditionalconstraintsonsurfaceanglestoeliminatesupportstructures(Langelaar TUDelft)
DesignforAdditiveManufacturing: Tools&Methods
General Assembly 2015, CapeTown, South Africa Dn 2016: Design for Additive ManufacturingCIRP2016WinterMeeting
Methodsandtoolsforthedesignofscaffoldandlatticestructures,FGMs,porousmaterials,etc.
(~25refs)
LightweightapplecreatedwiththeMagics StructuresmoduleDesign,analysisandadditivemanufacturingofporousstructuresforbiocompatiblemicro-scalescaffolds(Podshivalov)
DesignforAdditiveManufacturing: Tools&Methods
General Assembly 2015, CapeTown, South Africa Dn 2016: Design for Additive ManufacturingCIRP2016WinterMeeting
Design,simulation&optimizationrelatedtowarpage,shrinkage,accuracy,surfacequality,precisionetc.
SelectiveLaserMeltingofCrack-FreeHighDensityM2HighSpeedSteelPartsbyBaseplatePreheating(K.Kempen)
Poorsurfacequalityofdownfacingsurfaces(D.Thomas)
DesignforAdditiveManufacturing: Tools&Methods
General Assembly 2015, CapeTown, South Africa Dn 2016: Design for Additive ManufacturingCIRP2016WinterMeeting
ModelsandtoolsforverifyingandvalidatingDesignforAM
JG&AMetrologyCenter:Porosityanalysis
DesignforAdditiveManufacturing: Tools&Methods
General Assembly 2015, CapeTown, South Africa Dn 2016: Design for Additive ManufacturingCIRP2016WinterMeeting
DesignforAdditiveManufacturing: Tools&Methods
DfAM RelatedStandards
Areactivelybeingdevelopednow.By2020,itwillbetimetomaturelyintegratetheguidelinesdefinedbythestandards
General Assembly 2015, CapeTown, South Africa Dn 2016: Design for Additive ManufacturingCIRP2016WinterMeeting
• Designrulesforoverhangsandchannels• DesignforBioAM• Fileformat(STLandAMF)issues.• Knowledgebases&knowledgetransfer• Designingformaterialproperties• Designrulesforlayersandbuildorientations.• DesigningforInfill.• DesigningforqualitywithAM• Specialdesignfeatures.• ProcessplanningandmethodsforDfAM• Thebuildasadesignartifact(partpacking,support,etc.)• Environmentalimpact.• Materialre-use.
DesignforAdditiveManufacturing: Tools&Methods
Other
General Assembly 2015, CapeTown, South Africa Dn 2016: Design for Additive ManufacturingCIRP2016WinterMeeting
Ifwegetpreliminaryapproval,wewillformallyestablishtheteamandstartworkingonadetailedoutline.
Wewillprovideatimelineatthenextpresentation.
Timeline