Abstract
Additive Manufacturing (AM) brought a revolution in parts design and production. It enables the possibility to obtain objects with complex geometries and to exploit structural optimization algorithms. Nevertheless, AM is far from being a mature technology and advances are still needed from different perspectives. Among these, the literature highlights the need of improving the frameworks that describe the design process and taking full advantage of the possibilities offered by AM. This work aims to propose a workflow for AM guiding the designer during the embodiment design phase, from the engineering requirements to the production of the final part. The main aspects are the optimization of the dimensions and the topology of the parts, to take into consideration functional and manufacturing requirements, and to validate the geometric model by computer-aided engineering software. Moreover, a case study dealing with the redesign of a piston rod is presented, in which the proposed workflow is adopted. Results show the effectiveness of the workflow when applied to cases in which structural optimization could bring an advantage in the design of a part and the pros and cons of the choices made during the design phases were highlighted.
Highlights
From the works of the early pioneers, additive manufacturing (AM) technologies were characterized by great growth in the last 35 years [1]
A highly skilled workforce is required, file formats for exchanging the data related to the AM workflow need enhancements [8,9], and design methods and tools for complex structures, multi-material parts, and functionally graded materials need to be improved [10,11]
The concerns over the structural integrity of these complex parts require static and dynamic mechanical characterization [12,13]; experimental tests help to mechanically characterize the materials, skilled workforce is required, file formats for exchanging the data related to the AM workflow need enhancements [8,9], and design methods and tools for complex structures, multi-material parts, and functionally graded materials need to be improved [10,11].2 of
Summary
From the works of the early pioneers, additive manufacturing (AM) technologies were characterized by great growth in the last 35 years [1]. Depending on the method of layer manufacturing, it is possible to organize the AM technologies in the following categories: vat photopolymerization, material jetting, binder jetting, powder bed fusion, material extrusion, directed energy deposition, and sheet lamination [2]. This technology brings new opportunities especially in design freedom, allowing very complex shapes, integrating cinematics and multi-material parts, reducing the number of components through part consolidation, and increasing mass customization. The concerns over the structural integrity of these complex parts require static and dynamic mechanical characterization [12,13]; experimental tests help to mechanically characterize the materials, skilled workforce is required, file formats for exchanging the data related to the AM workflow need enhancements [8,9], and design methods and tools for complex structures, multi-material parts, and functionally graded materials need to be improved [10,11].2 of
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