Exploration of Various Methods for Cost Considerations in Additive Manufacturing

Abstract

Technology advancements in additive manufacturing allow for useful design optimization, especially in the field of integration (single components with multiple functions). The design process of a component includes considerations of design aspects, such as part geometry with respect to anticipated load conditions, chemical affinity due to possible adverse interaction of non-similar metals, weather conditions not predicted by applied coatings or protection systems and manufacturing design constraints. Due to reduced manufacturing constraints, additive manufacturing brings advantages such as reduced assembly time, higher part performance, and much greater geometric freedom. The following study explores the advantages and quantifies the cost optimization factors, such as manufacturing and assembly costs and material considerations, when assemblies and/or single components are replaced with an additively manufactured part, in mass produced and small volume applications. A relative part replacement cost function will be produced to show the feasibility of changeover to an additive manufactured part, furthermore two case studies will be analyzed and a new case study will be conducted and compared. Additive manufacturing costs, due to the popularization of different techniques, are constantly dropping and, therefore, are becoming valuable options in small to medium scale manufacturing operations as a way to reduce assembly costs and increase design performance.