Effectiveness of virtual models in design for additive manufacturing: a laser sintering case study

Abstract

PurposeAdditive Manufacturing (AM) technologies have conventionally focused on producing prototypes. However, recent trends show that AM is being increasingly used for production parts. With this shift from prototypes to production parts, there is a need to determine whether established engineering design techniques can be applied to AM processes, particularly techniques characteristic of the final implementation phase such as virtual (mathematical) modeling, or whether AM process‐specific adjustments must be made.Design/methodology/approachThe effectiveness of applying virtual models to design problems utilizing AM processes was addressed using two approaches in this research. Literature was first reviewed to determine the current focus of the AM industry on virtual modeling, both analytical and numerical, and its implementation. Second, experiments were conducted to validate virtual models applied to fastener mechanism designs manufactured using laser sintering (LS).FindingsLimited research has been published that demonstrates the effectiveness of applying established design techniques, particularly virtual modeling techniques, to parts manufactured with AM processes. The experimental case study has demonstrated that, for the limited cases considered, design techniques capable of accommodating the complex material properties of LS materials, such as finite element analysis, are effective methods for predicting part performance in accordance with desired outcomes.Practical implicationsThe research indicates that designers can focus on designing quality LS parts with existing technology and methods rather than revamping their design methods due to the introduction of a new manufacturing technology.Originality/valueThis research provides support for the application of established design methods to LS AM processes; validating what has previously been an assumed part of AM.