Abstract
PurposeThis paper aims to review recent research in design for additive manufacturing (DfAM), including additive manufacturing (AM) terminology, trends, methods, classification of DfAM methods and software. The focus is on the design engineer’s role in the DfAM process and includes which design methods and tools exist to aid the design process. This includes methods, guidelines and software to achieve design optimization and in further steps to increase the level of design automation for metal AM techniques. The research has a special interest in structural optimization and the coupling between topology optimization and AM.Design/methodology/approachThe method used in the review consists of six rounds in which literature was sequentially collected, sorted and removed. Full presentation of the method used could be found in the paper.FindingsExisting DfAM research has been divided into three main groups – component, part and process design – and based on the review of existing DfAM methods, a proposal for a DfAM process has been compiled. Design support suitable for use by design engineers is linked to each step in the compiled DfAM process. Finally, the review suggests a possible new DfAM process that allows a higher degree of design automation than today’s process. Furthermore, research areas that need to be further developed to achieve this framework are pointed out.Originality/valueThe review maps existing research in design for additive manufacturing and compiles a proposed design method. For each step in the proposed method, existing methods and software are coupled. This type of overall methodology with connecting methods and software did not exist before. The work also contributes with a discussion regarding future design process and automation.
Highlights
Additive manufacturing (AM) is an umbrella term for different manufacturing methods that aim to manufacture complex threedimensional shapes by adding material successively
Design for additive manufacturing (DfAM) is a term that has its origin in the term design for manufacturing (DfM), which means designing a part or a product for easy manufacturing (Boothroyd, 1994)
The paper has reviewed over 1,500 publications in the area of design for AM, design automation for AM, and optimization and AM
Summary
Additive manufacturing (AM) is an umbrella term for different manufacturing methods that aim to manufacture complex threedimensional shapes by adding material successively. Many circumstances, such as usable material, material properties and design constraints, differ depending on the chosen AM technique. Common to most of the techniques is the layer-bylayer approach, which is used during manufacturing. DfAM is the category specialized in components manufactured with AM. Compared to most other manufacturing technologies, AM has relatively few manufacturing constraints, which allows for a more optimization driven design process and could result in more valuable components
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