Design for additive manufacturing

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Design for additive manufacturing (DfAM or DFAM) is design for manufacturability as applied to additive manufacturing (AM). It is a general type of design methods or tools whereby functional performance and/or other key product life-cycle considerations such as manufacturability, reliability, and cost can be optimized subjected to the capabilities of additive manufacturing technologies. [1]

Contents

This concept emerges due to the enormous design freedom provided by AM technologies. To take full advantages of unique capabilities from AM processes, DfAM methods or tools are needed. Typical DfAM methods or tools includes topology optimization, design for multiscale structures (lattice or cellular structures), multi-material design, mass customization, part consolidation, and other design methods which can make use of AM-enabled features.

DfAM is not always separate from broader DFM, as the making of many objects can involve both additive and subtractive steps. Nonetheless, the name "DfAM" has value because it focuses attention on the way that commercializing AM in production roles is not just a matter of figuring out how to switch existing parts from subtractive to additive. Rather, it is about redesigning entire objects (assemblies, subsystems) in view of the newfound availability of advanced AM. That is, it involves redesigning them because their entire earlier design—including even how, why, and at which places they were originally divided into discrete parts—was conceived within the constraints of a world where advanced AM did not yet exist. Thus instead of just modifying an existing part design to allow it to be made additively, full-fledged DfAM involves things like reimagining the overall object such that it has fewer parts or a new set of parts with substantially different boundaries and connections. The object thus may no longer be an assembly at all, or it may be an assembly with many fewer parts. Many examples of such deep-rooted practical impact of DfAM have been emerging in the 2010s, as AM greatly broadens its commercialization. For example, in 2017, GE Aviation revealed that it had used DfAM to create a helicopter engine with 16 parts instead of 900, with great potential impact on reducing the complexity of supply chains. [2] It is this radical rethinking aspect that has led to themes such as that "DfAM requires 'enterprise-level disruption'." [3] In other words, the disruptive innovation that AM can allow can logically extend throughout the enterprise and its supply chain, not just change the layout on a machine shop floor.

DfAM involves both broad themes (which apply to many AM processes) and optimizations specific to a particular AM process. For example, DFM analysis for stereolithography maximizes DfAM for that modality.

Background

Additive manufacturing is defined as a material joining process, whereby a product can be directly fabricated from its 3D model, usually layer upon layer. [4] Comparing to traditional manufacturing technologies such as CNC machining or casting, AM processes have several unique capabilities. It enables the fabrication of parts with a complex shape as well as complex material distribution. [5] These unique capabilities significantly enlarge the design freedom for designers. However, they also bring a big challenge. Traditional Design for manufacturing (DFM) rules or guidelines deeply rooted in designers’ mind and severely restrict designers to further improve product functional performance by taking advantages of these unique capabilities brought by AM processes. Moreover, traditional feature-based CAD tools are also difficult to deal with irregular geometry for the improvement of functional performance. To solve these issues, design methods or tools are needed to help designers to take full advantages of design freedom provide by AM processes. These design methods or tools can be categorized as Design for Additive Manufacturing.

Methods

Topology optimization

Topology optimization is a type of structural optimization technique which can optimize material layout within a given design space. Compared to other typical structural optimization techniques, such as size optimization or shape optimization, topology optimization can update both shape and topology of a part. However, the complex optimized shapes obtained from topology optimization are always difficult to handle for traditional manufacturing processes such as CNC machining. To solve this issue, additive manufacturing processes can be applied to fabricate topology optimization result. [6] However, it should be noticed, some manufacturing constraints such as minimal feature size also need to be considered during the topology optimization process. [7] Since the topology optimization can help designers to get an optimal complex geometry for additive manufacturing, this technique can be considered one of DfAM methods.

Multiscale structure design

Due to the unique capabilities of AM processes, parts with multiscale complexities can be realized. This provides a great design freedom for designers to use cellular structures or lattice structures on micro or meso-scales for the preferred properties. For example, in the aerospace field, lattice structures fabricated by AM process can be used for weight reduction. [8] In the bio-medical field, bio-implant made of lattice or cellular structures can enhance osseointegration. [9]

Multi-material design

Parts with multi-material or complex material distribution can be achieved by additive manufacturing processes. To help designers take advantage of this capability, several design and simulation methods [10] [11] [12] have been proposed to support the design of a part with multiple materials or Functionally Graded Materials . These design methods also bring a challenge to traditional CAD system. Most of them can only deal with homogeneous materials now.

Design for mass customization

Since additive manufacturing can directly fabricate parts from products’ digital model, it significantly reduces the cost and leading time of producing customized products. Thus, how to rapidly generate customized parts becomes a central issue for mass customization. Several design methods [13] have been proposed to help designers or users to obtain the customized product in an easy way. These methods or tools can also be considered as the DfAM methods.

Parts consolidation

Due to the constraints of traditional manufacturing methods, some complex components are usually separated into several parts for the ease of manufacturing as well as assembly. This situation has been changed by the using of additive manufacturing technologies. Some case studies have been done to shows some parts in the original design can be consolidated into one complex part and fabricated by additive manufacturing processes. This redesigning process can be called as parts consolidation. The research shows parts consolidation will not only reduce part count, it can also improve the product functional performance. [14] The design methods which can guide designers to do part consolidation can also be regarded as a type of DfAM methods.

Lattice structures

Lattice structures is a type of cellular structures (i.e. open). These structures were previously difficult to manufacture, hence was not widely used. Thanks to the free-form manufacturing capability of additive manufacturing technology, it is now possible to design and manufacture complex forms. Lattice structures have high strength and low mass mechanical properties and multifunctionality. [15] These structures can be found in parts in the aerospace and biomedical industries. [16] [17] It has been observed that these lattice structures mimic atomic crystal lattice, where the nodes and struts represent atoms and atomic bonds, respectively, and termed as meta-crystals. They obey the metallurgical hardening principles (grain boundary strengthening, precipitate hardening etc.) when undergoing deformation. [18] It has been further reported that the yield strength and ductility of the struts (meta-atomic bonds) can be increased drastically by taking advantage of the non-equilibrium solidification phenomenon in Additive Manufacturing, thus increasing the performance of the bulk structures. [19]

Thermal issues in design

For AM processes that use heat to fuse powder or feedstock, process consistency and part quality are strongly influenced by the temperature history inside the part during manufacture, especially for metal AM. [20] [21] Thermal modelling can be used to inform part design and the choice of process parameters for manufacture, in place of expensive empirical testing. [22] [23] [24]

Optimal design for additive manufacturing

Additively manufactured metallic structures with the same (macroscopic) shape and size but fabricated by different process parameters have strikingly different microstructures and hence mechanical properties. [25] The abundant and highly flexible AM process parameters substantially influence the AM microstructures. [25] Therefore, in principle, one could simultaneously 3D-print the (macro-)structure as well as the desirable microstructure depending on the expected performance of the specialized AM component under the known service load. In this context, multi-scale and multi-physics integrated computational materials engineering (ICME) for computational linkage of process-(micro)structure-properties-performance (PSPP) chain can be used to efficiently search an AM design subspace for the optimum point with respect to the performance of the AM structure under the known service load. [26] The comprehensive design space of metal AM is boundless and high dimensional, which includes all the possible combinations of alloy compositions, process parameters and structural geometries. However, always a constrained subset of the design space (design subspace) is under consideration. The performance, as the design objective, depending on the thermo-chemo-mechanical service load, may include multiple functional aspects, such as specific energy absorption capacity, fatigue life/strength, high temperature strength, creep resistance, erosion/wear resistance and/or corrosion resistance. It is hypothesized that the optimal design approach is essential for unraveling the full potential of metal AM technologies and thus their widespread adoption for production of structurally critical load-bearing components. [26]

Related Research Articles

<span class="mw-page-title-main">Selective laser sintering</span> 3D printing technique

Selective laser sintering (SLS) is an additive manufacturing (AM) technique that uses a laser as the power and heat source to sinter powdered material, aiming the laser automatically at points in space defined by a 3D model, binding the material together to create a solid structure. It is similar to selective laser melting; the two are instantiations of the same concept but differ in technical details. SLS is a relatively new technology that so far has mainly been used for rapid prototyping and for low-volume production of component parts. Production roles are expanding as the commercialization of AM technology improves.

Topology optimization is a mathematical method that optimizes material layout within a given design space, for a given set of loads, boundary conditions and constraints with the goal of maximizing the performance of the system. Topology optimization is different from shape optimization and sizing optimization in the sense that the design can attain any shape within the design space, instead of dealing with predefined configurations.

<span class="mw-page-title-main">3D printing</span> Additive process used to make a three-dimensional object

3D printing or additive manufacturing is the construction of a three-dimensional object from a CAD model or a digital 3D model. It can be done in a variety of processes in which material is deposited, joined or solidified under computer control, with the material being added together, typically layer by layer.

<span class="mw-page-title-main">Design for manufacturability</span> Designing products to facilitate manufacturing

Design for manufacturability is the general engineering practice of designing products in such a way that they are easy to manufacture. The concept exists in almost all engineering disciplines, but the implementation differs widely depending on the manufacturing technology. DFM describes the process of designing or engineering a product in order to facilitate the manufacturing process in order to reduce its manufacturing costs. DFM will allow potential problems to be fixed in the design phase which is the least expensive place to address them. Other factors may affect the manufacturability such as the type of raw material, the form of the raw material, dimensional tolerances, and secondary processing such as finishing.

Electron-beam additive manufacturing, or electron-beam melting (EBM) is a type of additive manufacturing, or 3D printing, for metal parts. The raw material is placed under a vacuum and fused together from heating by an electron beam. This technique is distinct from selective laser sintering as the raw material fuses have completely melted. Selective Electron Beam Melting (SEBM) emerged as a powder bed-based additive manufacturing (AM) technology and was brought to market in 1997 by Arcam AB Corporation headquartered in Sweden.

<span class="mw-page-title-main">Rapid prototyping</span> Group of techniques to quickly construct physical objects

Rapid prototyping is a group of techniques used to quickly fabricate a scale model of a physical part or assembly using three-dimensional computer aided design (CAD) data. Construction of the part or assembly is usually done using 3D printing or "additive layer manufacturing" technology.

Architectural design optimization (ADO) is a subfield of engineering that uses optimization methods to study, aid, and solve architectural design problems, such as optimal floorplan layout design, optimal circulation paths between rooms, sustainability and the like. ADO can be achieved through retrofitting, or it can be incorporated within the initial construction a building. Methods of ADO might include the use of metaheuristic, direct search or model-based optimisation. It could also be a more rudimentary process involving identification of a perceived or existing problem with a buildings design in the concept design phase.

<span class="mw-page-title-main">Generative design</span> Iterative design process

Generative design is an iterative design process that uses software to generate outputs that fulfill a set of constraints iteratively adjusted by a designer. Whether a human, test program, or artificial intelligence, the designer algorithmically or manually refines the feasible region of the program's inputs and outputs with each iteration to fulfill evolving design requirements. By employing computing power to evaluate more design permutations than a human alone is capable of, the process is capable of producing an optimal design that mimics nature's evolutionary approach to design through genetic variation and selection. The output can be images, sounds, architectural models, animation, and much more. It is, therefore, a fast method of exploring design possibilities that is used in various design fields such as art, architecture, communication design, and product design.

<span class="mw-page-title-main">Selective laser melting</span> 3D printing technique

Selective laser melting (SLM) is one of many proprietary names for a metal additive manufacturing (AM) technology that uses a bed of powder with a source of heat to create metal parts. Also known as direct metal laser sintering (DMLS), the ASTM standard term is powder bed fusion (PBF). PBF is a rapid prototyping, 3D printing, or additive manufacturing technique designed to use a high power-density laser to melt and fuse metallic powders together.

<span class="mw-page-title-main">Conformal cooling channel</span>

Conformal cooling channel is a cooling passageway which follows the shape or profile of the mould core or cavity to perform rapid uniform cooling process for injection moulding or blow moulding processes.

Robocasting is an additive manufacturing technique analogous to Direct Ink Writing and other extrusion-based 3D-printing techniques in which a filament of a paste-like material is extruded from a small nozzle while the nozzle is moved across a platform. The object is thus built by printing the required shape layer by layer. The technique was first developed in the United States in 1996 as a method to allow geometrically complex ceramic green bodies to be produced by additive manufacturing. In robocasting, a 3D CAD model is divided up into layers in a similar manner to other additive manufacturing techniques. The material is then extruded through a small nozzle as the nozzle's position is controlled, drawing out the shape of each layer of the CAD model. The material exits the nozzle in a liquid-like state but retains its shape immediately, exploiting the rheological property of shear thinning. It is distinct from fused deposition modelling as it does not rely on the solidification or drying to retain its shape after extrusion.

<span class="mw-page-title-main">Freeform surface machining</span> Machining techniques for complex surfaces

In manufacturing, freeform surface machining refers to the machining of complex surfaces that are not uniformly planar. The industries which most often manufactures free-form surfaces are basically aerospace, automotive, die mold industries, biomedical and power sector for turbine blades manufacturing. Generally 3- or 5-axis CNC milling machines are used for this purpose. The manufacturing process of freeform surfaces is not an easy job, as the tool path generation in present CAM technology is generally based on geometric computation so tool path are not optimum. The geometry can also be not described explicitly so errors and discontinuities occurrence in the solid structure cannot be avoided. Free-form surfaces are machined with the help of different tool path generation method like adaptive iso-planar tool path generation, constant scallop tool path generation, adaptive iso-parametric method, iso-curvature, isophote and by other methods. The different methods are chosen based on the parameters which is needed to be optimized.

Rule based DFM analysis for direct metal laser sintering. Direct metal laser sintering (DMLS) is one type of additive manufacturing process that allows layer by layer printing of metal parts having complex geometries directly from 3D CAD data. It uses a high-energy laser to sinter powdered metal under computer control, binding the material together to create a solid structure. DMLS is a net shape process and allows the creation of highly complex and customized parts with no extra cost incurred for its complexity.

<span class="mw-page-title-main">DFM analysis for stereolithography</span>

In design for additive manufacturing (DFAM), there are both broad themes and optimizations specific to a particular AM process. Described here is DFM analysis for stereolithography, in which design for manufacturability (DFM) considerations are applied in designing a part to be manufactured by the stereolithography (SLA) process. In SLA, parts are built from a photocurable liquid resin that cures when exposed to a laser beam that scans across the surface of the resin (photopolymerization). Resins containing acrylate, epoxy, and urethane are typically used. Complex parts and assemblies can be directly made in one go, to a greater extent than in earlier forms of manufacturing such as casting, forming, metal fabrication, and machining. Realization of such a seamless process requires the designer to take in considerations of manufacturability of the part by the process. In any product design process, DFM considerations are important to reduce iterations, time and material wastage.

Virtual machining is the practice of using computers to simulate and model the use of machine tools for part manufacturing. Such activity replicates the behavior and errors of a real environment in virtual reality systems. This can provide useful ways to manufacture products without physical testing on the shop floor. As a result, time and cost of part production can be decreased.

Digital manufacturing is an integrated approach to manufacturing that is centered around a computer system. The transition to digital manufacturing has become more popular with the rise in the quantity and quality of computer systems in manufacturing plants. As more automated tools have become used in manufacturing plants it has become necessary to model, simulate, and analyze all of the machines, tooling, and input materials in order to optimize the manufacturing process. Overall, digital manufacturing can be seen sharing the same goals as computer-integrated manufacturing (CIM), flexible manufacturing, lean manufacturing, and design for manufacturability (DFM). The main difference is that digital manufacturing was evolved for use in the computerized world.

<span class="mw-page-title-main">3D printing processes</span> List of 3D printing processes

A variety of processes, equipment, and materials are used in the production of a three-dimensional object via additive manufacturing. 3D printing is also known as additive manufacturing, because the numerous available 3D printing process tend to be additive in nature, with a few key differences in the technologies and the materials used in this process.

<span class="mw-page-title-main">Microstructures in 3D printing</span>

The use of microstructures in 3D printing, where the thickness of each strut scale of tens of microns ranges from 0.2mm to 0.5mm, has the capabilities necessary to change the physical properties of objects (metamaterials) such as: elasticity, resistance, and hardness. In other words, these capabilities allow physical objects to become lighter or more flexible. The pattern has to adhere to geometric constraints, and thickness constraints, or can be enforced using optimization methods. Innovations in this field are being discovered in addition to 3D printers being built and researched with the intent to specialize in building structures needing altered physical properties.

3D printing speed measures the amount of manufactured material over a given time period, where the unit of time is measured in Seconds, and the unit of manufactured material is typically measured in units of either kg, mm or cm3, depending on the type of additive manufacturing technique.

Multi-material 3D printing is the additive manufacturing procedure of using multiple materials at the same time to fabricate an object. Similar to single material additive manufacturing it can be realised through methods such as FFF, SLA and Inkjet 3D printing. By expanding the design space to different materials, it establishes the possibilities of creating 3D printed objects of different color or with different material properties like elasticity or solubility. The first multi-material 3D printer Fab@Home became publicly available in 2006. The concept was quickly adopted by the industry followed by many consumer ready multi-material 3D printers.

References

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