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