Evaluating design uncertainties in additive manufacturing using design artefacts: examples from space industry

Abstract

The use of metal Additive Manufacturing (AM) has increased in recent years with potential benefits for novel design solutions and efficient manufacturing. In order to utilise these potentials, engineers need to address uncertainties related to product design and the AM process. This paper presents a design process utilising product-specific AM Design Artefacts (AMDAs) to assess uncertainties identified during design. The process emphasises the importance of concurrently developing the product and AM knowledge. Based on a research collaboration with industry, three case studies describe the use of this process in the development of products for AM. In total, six different types of AMDAs show how AM-related uncertainties are resolved to provide confidence in design solutions and manufacturability. The contributions of this paper are: (i) a design process where AMDAs are used as support in evolving and defining an AM design specification, (ii) an example of how Design for AM (DfAM) is practiced in industry and of typical AM uncertainties that are encountered and addressed, and (iii) an example of how collaborative research can facilitate new knowledge for both industry and academia. The practical implication is a DfAM process for engineers to use and adapt according to existing AM knowledge.