Abstract
Although several research works in the literature have focused on studying the capabilities of additive manufacturing (AM) systems, few works have addressed the development of Design for Additive Manufacturing (DfAM) knowledge, tools, rules, and methodologies, which has limited the penetration and impact of AM in industry. In this paper a comprehensive review of design and manufacturing strategies for Fused Deposition Modelling (FDM) is presented. Consequently, several DfAM strategies are proposed and analysed based on existing research works and the operation principles, materials, capabilities and limitations of the FDM process. These strategies have been divided into four main groups: geometry, quality, materials and sustainability. The implementation and practicality of the proposed DfAM is illustrated by three case studies. The new proposed DfAM strategies are intended to assist designers and manufacturers when making decisions to satisfy functional needs, while ensuring manufacturability in FDM systems. Moreover, many of these strategies can be applied or extended to other AM processes besides FDM.
Highlights
The need to increase flexibility and speed up the design and manufacture process of new products led to the development of rapid technologies, including the additive manufacturing (AM) techniques
The AM technologies were known as Rapid Prototyping (RP) technologies since they were used for visualization and design validation purposes; the fast evolution of these technologies allowed the rapid manufacture (RM) of end-use parts and the rapid development of tooling
3 Design for Additive Manufacturing (DfAM) According to Ref. [29], the objectives and goals of DfAM comprise the three levels of abstractions of traditional Design for Manufacturing and Assembly (DfMA): 1) to offer tools, techniques and guidelines to adapt a design to a given set of downstream manufacturing constraints; 2) to understand and quantify the effect of the design process on manufacturing in order to improve the performance of the manufacturing system and product quality; and 3) to know the relationship between design and manufacturing and its impact on the designer, the design process and the design practice
Summary
The need to increase flexibility and speed up the design and manufacture process of new products led to the development of rapid technologies, including the additive manufacturing (AM) techniques ( known as rapid prototyping, rapid manufacturing, rapid tooling, additive fabrication, additive layer manufacturing, layer manufacturing, and freeform fabrication technologies). The design and manufacture stages during a new product development process are critical because any decisions at this point can have a great impact on the final cost and quality of the product. In order to assist designers in this decision-making process, basic rules and design guidelines, known as Design for X, have been proposed in the literature. These design guidelines are focused on manufacturability, assembly, sustainability, minimum risk, avoiding corrosion, recycling, standardization, durability, materials, maintenance, minimum cost, among others. The challenge of design for AM technologies is to create quality parts that satisfy the design requirements such as functionality, geometry, mechanical properties and cost, while assuring manufacturability in AM systems
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