Design For Manufacturing And Assembly Research Articles

Additive Manufacturing Oriented Parametric Design Automation of Adaptive Joint System for an Irregular Form Gridshell Structure

In architectural engineering, triangular tessellation using polygon mesh topology is one of the commonly used computational geometric approaches to simplify a free curved building façade into flat triangular facets and their subsequent straight edges. In such a façade system, exterior panels are supported by a network of profiles that correspond to their edges hidden behind the panels at an offset distance. A group of profiles, derived from the edges common to a node point of tessellated panels (i.e., the outermost panels enveloping the building), may dislocate from each other when offset from their original locations due to non-coplanar alignment and unique offset directions and distances. This dislocation problem gives rise to geometric complications in nodal connector design in addition to varying in the connected profile count and orientations. Design considerations regarding the effects of ’offset vertex dislocation’ (i.e., the dislocation of the edges when it offsets from the original topology due to incoherent normal direction) should incorporate proper variables in the correct sequence based on a fundamental understanding that causes the dislocation problem. However, it is very often these topological problems pertaining to offset that are neglected, leading to subsequent design flaws. Such oversights diminish the inherent strengths of DfMA (design for manufacture and assembly) and design automation. This study develops a computational mathematical approach aimed at addressing the geometric complexities in nodal connector design. It focuses on two main areas: the precise positioning of substructure profiles essential for the design and a design automation approach that minimizes the length of the nodal connector arms to enhance 3D printing productivity. A life-scale proof-of-concept structure based on an automated parametric design process that implements the research findings demonstrates the application, incorporating 3D-printed PA12 (Polyamide-12) nodal connectors.

Design for Manufacturing and Assembly Optimization of Home-Scale Biodigester-Composter Using VDI 2222 and Finite Element Analysis Methods

This research focused on the Design for Manufacturing and Assembly (DFMA) optimization of home-scale biodigester-composter machines. The aims to determine feasibility from technical-economic aspects. The technique was to design the machine's mechanical process, physical, and constituent components. There are two methods conducted on this research, VDI 2222 to optimize and Finite Element Analysis (FEA) to assess the optimal quality results of the machine design based on simulation analysis. This research ended with making a physical prototype of a home-scale biodigester-composter machine using the optimal design, then validating it with a working test of the machine. The results of the VDI 2222 method show an optimal design concept through the structure of the working mechanism. All its constituent components match with the ten target specifications and the machine manufacturing cost of IDR 2,393,000, as well as the assembly chart design for each constituent component. These results are also evaluated using the FEA method. The resistance value of the frame system to maximum Von Mises Stress is obtained at 128.75 MPa with a minimum value of 6.93e-04 MPa. It is concluded to be acceptable at withstanding normal and shear stresses effectively with a relatively small displacement value of 0 to 0.47 mm. The equivalent strain value results are 3.89e-09 ul to 5.83e-04 ul and safety factor value results are 1.93 to 15 ul. It can be concluded that the frame system design concept is safe.

THE IMPLEMENTATION OF DESIGN FOR MANUFACTURING AND ASSEMBLY (DfMA) IN INDONESIAN CONSTRUCTION INDUSTRY: MAJOR BARRIERS AND DRIVING FACTORS

Construction industry is a crucial sector of a country’s economy, but faces continuing problems such as low productivity, labor intensity, and fragmented processes. Design for Manufacturing and Assembly (DfMA) has been identified as an important strategy for solving this problem. Despite its potential, the adoption of DfMA in Indonesian construction industry has been slow. Therefore, this study aimed to (1) investigate barriers to the adoption of DfMA and (2) propose effective drivers to promote the adoption of DfMA. To achieve these objectives, a comprehensive literature review and structured interviews were conducted with DfMA experts. A questionnaire survey was then carried out with 100 respondents, and after applying purposive sampling criteria, 71 respondents were considered eligible. Following this discussion, the primary data was analyzed using descriptive and inferential statistics. The collected data was processed using structural equation modelling (SEM) application known as SMARTPLS. The result showed that the main obstacle faced was the organizational mindset, while the most effective strategy was the contribution and support of the government. This study provided a better understanding of the constraints faced and driving factors that could be considered effective by industry practitioners. Additionally, there was an expectation that the results of this exploration would be an important starting point for developing a roadmap to encourage the wider adoption of DfMA in construction industry in Indonesia.

Levelized Cost and Carbon Intensity of Solar Hydrogen Production from Water Electrolysis Using a Scalable and Intrinsically Safe Photocatalytic Z-Scheme Raceway System

The realization of an environmentally sustainable and widely-adopted hydrogen economy may require lowering hydrogen production costs of production pathways with ultra-low greenhouse gas emissions to $1/kg H2. The allocation of new or existing renewable electricity generation solely to hydrogen production remains contentious due to disputes regarding emissions accounting. Photoelectrochemical (PEC) hydrogen production technologies offer a unique solution, as hydrogen is produced directly from solar energy and water, without the need for electricity generation. However, cost projections for past photoelectrochemical designs have suggested that they are not cost competitive compared to conventional electrolysis systems manufactured at scale. Herein, we offer the first illustrative benchmark of cost and carbon intensity of hydrogen produced in a Type 2 Z-scheme photocatalytic reactor design that employs suspended semiconducting nanoparticles organized in two stacked baggies in a raceway design.To explore the near-term and future cost projection for hydrogen production via Type 2 photocatalytic Z-scheme raceways, the authors developed a bottom-up total installed capital cost model. This project cost model incorporates: 1) raceway reactor cost, derived from a Design for Manufacturing and Assembly (DFMA) process-based cost model, 2) mechanical balance of plant, including process equipment, piping, valves, and instrumentation, derived from equipment quotes, scaling, database values, and Aspen estimates; 3) electrical balance of plant, including wiring, derived from time and material cost correlations; 4) Site Preparation, focused on green field installation; and 5) Construction Overhead, including engineering, procurement, and construction (EPC) costs and project contingency. The capital cost model is fed into a Levelized Cost of Hydrogen (LCOH) discounted cash flow model that accounts for electricity and water consumption, in addition to other operating costs, including labor, maintenance, and raceway replacements.A hybrid life-cycle approach was used to develop an inventory of greenhouse gas emissions from all materials and energy flows associated with the facility life cycle. These flows are converted to emissions based on specific emission factors, or by using physical units-based input–output LCA models associated with the broader economic impacts of fuel and materials production, use, and end use.Estimates for levelized cost of hydrogen suggest that a 50 metric ton H2 per day (MTD) raceway plant can approach $2.50/kg H2 at an 8% solar-to-hydrogen efficiency with further cost improvements possible through increased performance and larger plant scales. Carbon intensity is estimated to be well under clean hydrogen targets for global warming potential of <2-4 kg CO2e/kg H2 produced. The results suggest a highly competitive and scalable technology, that justifies further experimental validation and prototyping in the field. Figure 1

Safety impacts of design for manufacture and assembly techniques in off-site construction

Design for manufacture and assembly (DfMA) is an approach for improving project safety performance. For off-site construction (OSC), the philosophy is increasingly becoming a preferred design approach for OSC components. However, studies examining the safety impact of DfMA in OSC are limited. This study investigated the potential effects of DfMA techniques on mitigating specific safety hazards in OSC. A literature review identified and paired DfMA techniques and the safety hazards they mitigate. Empirical data was collected using a survey to assess the identified relationships. Data was analyzed using a combination of frequencies, inferential statistics, and Cronbach’s alpha. Most respondents agreed that DfMA techniques control their pairwise safety hazards in OSC. To eliminate safety hazards and limit their socio-economic impact, contracting organisations engaged in OSC need to consider the application of DfMA in the manufacture, assembly, and disassembly processes of OSC. The study reaffirms the importance of implementing evidence-based DfMA techniques for mitigating safety hazards in developing countries where OSC is an emerging philosophy.

Enhancing learning in design for manufacturing and assembly: the effects of augmented reality and game-based learning on student’s intrinsic motivation

PurposeThis study aims to examine the effects on student motivation and perception of technological interventions within undergraduate mechanical engineering and product design and manufacture programs at a Sino-foreign international university. The authors use an augmented reality game application within a class on Design for Manufacturing and Assembly (DfMA) that was developed using the approaches of microlearning and digital game-based learning (DGBL).Design/methodology/approachStructured as design-based research, the study reports on developing innovative educational interventions and provides an empirical investigation of their effectiveness. Data were collected using a mixed methods approach, using pre- and post-tests and questionnaires, together with researcher observations and participant interviews.FindingsThrough two rounds of playtests, the game positively affected intrinsic motivation and encouraged higher-order cognitive learning, critical thinking, communication and collaboration. Collaborative learning plays a significant role, DGBL is preferred over traditional methods and microlearning reduces information density and cognitive overload.Originality/valueThe study contributes to our understanding of digital game-based interventions on students’ intrinsic motivation and provides insights into effective ways to design instructional materials in similar teaching and learning settings.

An Improvement of Hand Press Machine by Design for Manufacturing and Assembly (DFMA) Methodology

This research consists of the analysis of hand press machine selected using the Design for Manufacturing and Assembly (DFMA) method. DFMA is a method that combines both Design for Manufacturing (DFM) and Design for Assembly (DFA) techniques. It has the purpose to make improvements on the existing product by implementing DFMA to reduce number of components, time, and cost. The combination of hand press machine and a die cutting tool has been an effective tool to produce and replicate identical designs in the shortest time. The main objective of this research is to develop a Hand Press Machine that exhibits superior design efficiency and reduced manufacturing costs compared to the original design. To achieve this, the chosen existing model, the WUTA Pro Leather Cutting Machine, was remodelled using SolidWorks 2022 software. The original design of the Hand Press Machine had a design efficiency of 25.89%. However, the improved design achieved a significantly higher design efficiency of 36.56%, representing an increase of 10.67%. To attain this improvement, four modifications were implemented. One notable achievement in the improved design was a reduction in the total number of parts. The original design comprised 52 parts, whereas the improved design successfully reduced this to 34 parts, resulting in a reduction of 18 parts. The cost analysis, based on total absorption cost, revealed that the manufacturing cost of the original design was estimated at $362.01 for 18 manufactured parts. In contrast, the improved design was able to achieve a cost reduction, with an estimated manufacturing cost of around $339.16 for 16 manufactured parts. This indicates a cost reduction of $22.85 between the two models.

Anthropomorphic Robotic Hand Prosthesis Developed for Children.

The use of both hands is a common practice in everyday life. The capacity to interact with the environment is largely dependent on the ability to use both hands. A thorough review of the current state of the art reveals that commercially available prosthetic hands designed for children are very different in functionality from those developed for adults, primarily due to prosthetic hands for adults featuring a greater number of actuated joints. Many times, patients stop using their prosthetic device because they feel that it does not fit well in terms of shape and size. With the idea of solving these problems, the design of HandBot-Kid has been developed with the anthropomorphic qualities of a child between the ages of eight and twelve in mind. Fitting the features of this age range, the robotic hand has a length of 16 cm, width of 7 cm, thickness of 3.6 cm, and weight of 328 g. The prosthesis is equipped with a total of fifteen degrees of freedom (DOF), with three DOFs allocated to each finger. The concept of design for manufacturing and assembly (DFMA) has been integrated into the development process, enabling the number of parts to be optimized in order to reduce the production time and cost. The utilization of 3D printing technology in conjunction with aluminum machining enabled the manufacturing process of the robotic hand prototype to be streamlined. The flexion-extension movement of each finger exhibits a trajectory that is highly similar to that of a real human finger. The four-bar mechanism integrated into the finger design achieves a mechanical advantage (MA) of 40.33% and a fingertip pressure force of 10.23 N. Finally, HandBot-Kid was subjected to a series of studies and taxonomical tests, including Cutkosky (16 points) and Kapandji (4 points) score tests, and the functional results were compared with some commercial solutions for children mentioned in the state of the art.

DfMA Integrated Assessment Model for Selecting Optimal Design Alternatives in OSC Projects

To select the optimal design alternative in off-site construction (OSC) projects, the building industry has turned to design for manufacturing and assembly (DfMA). However, most DfMA developments in the OSC field until now have been on improving the production process in OSC projects and guideline strategies on how to apply them. The application of DfMA guidelines only provides background knowledge to designers on how to design. However, it cannot inspect whether the DfMA concept is fully reflected in a design draft to examine the suitability to the OSC production environment, and it cannot determine the optimal alternative from among multiple design alternatives. Thus, this study developed an integrated assessment model of OSC-DfMA consisting of the OSC-DfMA production suitability assessment model and the OSC-DfMA production efficiency assessment model to support decision-making for selecting the optimal design alternative of an OSC project. In this study, the scope of the main research was limited to precast concrete (PC)-based OSC projects. Firstly, we developed an OSC-DfMA production suitability assessment model to review whether design drafts are suitable in the OSC production environment by applying checklist and matrix techniques. Secondly, we developed an OSC-DfMA production efficiency assessment model to select an optimal alternative in terms of production efficiency among multiple design drafts. Thirdly, we conducted a case study to validate the usefulness of the OSC-DfMA assessment model developed in this study. Finally, we discuss the possibility of using AI technology to consider the facility capacity and resource constraints during the production of OSC building components. The study results are of practical value in providing the basis for expanding the applicability of DfMA by proposing a DfMA assessment model suitable for OSC contexts.

Detailed Design of Special-Shaped Steel Structures Based on DfMA: The BIM-FEM Model Conversion Method

(1) This paper, based on the characteristics of complex steel structures as well as difficult points in the process of their detailed design, introduces the product design concept of DfMA (Design for Manufacturing and Assembly) from the manufacturing industry and studies the detailed design method of BIM-FEM model conversion. The BIM software Revit (2020) is used as the basis for the BIM detailed design of the project, which achieves the purpose of rapid modeling and provides a detailed design model basis for finite element analysis. (2) Utilizing the Revit API and C# for secondary development as the technical means, this approach involves converting the geometric entity model described by CSG-Brep into an APDL stream. This creates an interface with the finite element analysis software ANSYS (12.0) to implement the detailed design of BIM-FEM model conversion, optimizing the algorithm for converting complex analysis models that require high precision for special-shaped steel structures. (3) This research addresses issues such as the disconnection between the design, manufacturing, and construction of special-shaped steel structures, providing support for design decisions. Moreover, it enhances the detailed design method by improving the standardization of special-shaped components under the condition of design diversity. (4) These studies provide sustainability for engineering design, manufacturing, and construction projects, enabling the maximization of benefits and product lifecycle management (PLM) through these projects. (5) Finally, a case study analysis was conducted on the Wuhan City New Generation Weather Radar Construction Project, designed by the Central South Architectural Design Institute (CSADI), to verify the detailed design of BIM-FEM model conversion. This proved the scientific validity, practicality, and necessity of this research.

DESIGN FOR MANUFACTURING AND ASSEMBLY (DfMA) – WHAT AFFECTS ITS ADOPTION IN THE CONSTRUCTION PROJECTS?

There is a consensus among industry leaders and scholars that the construction sector will lose its competitive advantages if its lethargy to adopt Industry 4.0 technologies continues. As a response, the construction industry has been advocating the more extensive use of the Design for Manufacturing and Assembly (DfMA) in projects. Research studies on this topic mainly reported technological advancement but rarely addressed the factors that lead to the development of positive organizational behavior towards the implementation of DfMA. A systematic literature review will be adopted to achieve the research aims. A total number of 18 behavioral traits were identified through the method, including client's interest, stakeholders support, availability of DfMA related resources, companies' capability, early involvement of all parties in design, development of DfMA-friendly procurement approach, the use of digital technology, government involvement, etc. The findings will shed light on DfMA adoption on behavioral aspects for global DfMA adoption in the construction industry.

DESIGN FOR MANUFACTURING AND ASSEMBLY (DfMA) – WHAT AFFECTS ITS ADOPTION IN THE CONSTRUCTION PROJECTS?

There is a consensus among industry leaders and scholars that the construction sector will lose its competitive advantages if its lethargy to adopt Industry 4.0 technologies continues. As a response, the construction industry has been advocating the more extensive use of the Design for Manufacturing and Assembly (DfMA) in projects. Research studies on this topic mainly reported technological advancement but rarely addressed the factors that lead to the development of positive organizational behavior towards the implementation of DfMA. A systematic literature review will be adopted to achieve the research aims. A total number of 18 behavioral traits were identified through the method, including client's interest, stakeholders support, availability of DfMA related resources, companies' capability, early involvement of all parties in design, development of DfMA-friendly procurement approach, the use of digital technology, government involvement, etc. The findings will shed light on DfMA adoption on behavioral aspects for global DfMA adoption in the construction industry.

Client-centered detached modular housing: natural language processing-enabled design recommender system

AbstractDesigning modular housing is a complex task that necessitates a thorough understanding of the diverse needs of clients in terms of both design aesthetics and floor plan layout. Furthermore, adhering to design for manufacture and assembly (DfMA) principles adds to the complexity, as these are essential modular home requirements. Traditional construction methods frequently fail to meet the specific needs of both clients and DfMA, potentially resulting in suboptimal design solutions. Incorporating client requirements during the design phase necessitates the use of an effective system and framework to reduce changes in subsequent project stages. Existing literature lacks a suitable approach, particularly in the context of modular housing. To address this gap, this paper introduces an artificial intelligence–building information modeling recommender system (RS) for detached modular housing design. The system processes client requirements entered as text utilizing the Word2vec algorithm with the GloVe dataset, refined through transfer learning using surveyed client data of housing needs. The system recommends three distinct modular building design alternatives sourced from a building information modeling models database using cosine and Euclidean similarity functions. A sensitivity analysis ensures that client needs are considered fairly, increasing the robustness of the RS. By incorporating natural language processing, this system transforms the construction industry by making initial designs more client-centric compared with traditional methods. Furthermore, it promotes improved collaboration among clients, design, and construction teams, reducing modifications to design in later stages of construction.

DeepCraft: imitation learning method in a cointelligent design to production process to deliver architectural scenarios

The recent advancements in digital technologies and artificial intelligence in the architecture, engineering, construction, and operation sector (AECO) have induced high demands on the digital skills of human experts, builders, and workers. At the same time, to satisfy the standards of the production-efficient AECO sector by reducing costs, energy, health risk, material resources, and labor demand through efficient production and construction methods such as design for manufacture and assembly (DfMA), it is necessary to resolve efficiency-related problems in mutual human‒machine collaborations. In this article, a method utilizing artificial intelligence (AI), namely, generative adversarial imitation learning (GAIL), is presented then evaluated in two independent experiments related to the processes of DfMA as an efficient human‒machine collaboration. These experiments include a) training the digital twin of a robot to execute a robotic toolpath according to human gestures and b) the generation of a spatial configuration driven by a human's design intent provided in a demonstration. The framework encompasses human intelligence and creativity, which the AI agent in the learning process observes, understands, learns, and imitates. For both experimental cases, the human demonstration, the agent's training, the toolpath execution, and the assembly configuration process are conducted digitally. Following the scenario generated by an AI agent in a digital space, physical assembly is undertaken by human builders as the next step. The implemented workflow successfully delivers the learned toolpath and scalable spatial assemblies, articulating human intelligence, intuition, and creativity in the cocreative design.

Large language models driven BIM-based DfMA method for free-form prefabricated buildings: framework and a usefulness case study

ABSTRACT The escalating demand for free-form buildings presents a formidable technological hurdle in the realm of prefabrication manufacturing and assembly. This research draws inspiration from recent advancements in large language models (LLMs) and seeks to harness their transformative potential in tandem with Building Information Modeling (BIM) to advance the Design for Manufacture and Assembly (DfMA) method. The ultimate aim is to catapult the prefabrication industry into an era characterized by unparalleled design freedom and heightened efficiency. The research includes contributions from the following four areas: (1) A review of the literature on DfMA theories, specifically fabrication and construction. (2) The development of a BIM-based DfMA method framework, including the methodological basis, Design for Manufacturing (DfM), and Design for Assembly (DfA). (3) A pipeline for LLMs driven BIM-based DfMA method framework and a validation using the Decathlon Solar Team design-build practice at the University of Washington’s Lotus House. (4) An evaluation of 692 conversation scenarios to verify the feasibility of our proposal. We get a 91.1% user agreement on average based on GPT4. The research results could guide the workflow in building a lifecycle for DfMA practices in the future smart manufacturing era.

MIVES MULTI-CRITERIA FRAMEWORK TO SUSTAINABILITY INDEX OF DESIGN FOR MANUFACTURE AND ASSEMBLY

Embracing sustainable strategies that consider Design for Manufacture and Assembly (DfMA) has become a rapidly growing trend in urban development. Continued uncertainty on the sustainability assessment of design could drive a series of indecisive decision-making among design alternatives, further disrupting the potential opportunities toward sustainable DfMA. However, there is a lack of research on sustainable design assessments for DfMA and establishing a sustainable index. This research establishes an integrated value model for the sustainability assessment framework and DfMA sustainability index to address this challenge. This model integrates Building Information Modelling (BIM) with MIVES, a customisable Multi-Criteria Decision Making (MCDM) tool. The pilot case of this framework is the retrofit of a commercial building’s façade system, which demonstrated the capability of the proposed framework. Data collection and analysis include the comparisons between five design alternatives. This research furthers previous studies and has three-fold significance: 1) Establishing reasonable multi-criteria for the sustainable DfMA indices; 2) Adapting the MIVES approach for comparative analysis across three building phases to make it compatible with DfMA; 3) developing a quantitative analysis method for sustainable design assessment of DfMA in the construction industry.

Design for Manufacturing and Assembly (DfMA) in Construction: A Holistic Review of Current Trends and Future Directions

The construction industry, despite its anticipated significant growth, has struggled with low productivity over the past two decades. Design for manufacturing and assembly (DfMA), a methodology with a history of success in other industries, presents a promising solution to enhancing efficiency in construction. This article reviews the current state of DfMA in the construction industry, identifies the most recent research themes in the field of DfMA, and provides recommendations for future DfMA research based on the existing research gaps. The paper employs a mixed-method approach, combining quantitative bibliometric analysis and qualitative thematic analysis. Using Scopus as the literature database, the study identified 43 relevant articles published between 2013 and 2023. The bibliometric analysis reveals a growing interest in DfMA research, with an upward trend in publications over the years. The thematic analysis categorizes DfMA research topics into six main themes: Innovation and Technology Trends, Sustainability and Environmental Impact, Regulatory and Policy Considerations, Collaborative Approach, Applications, Benefits, and Challenges, and Project Lifecycle. Each theme is explored in-depth, providing insights into the transformative impact of technology, environmental considerations in DfMA, regulatory challenges, collaborative strategies, varied applications, and the project lifecycle phases influenced by DfMA. The article concludes by presenting identified research gaps and offering recommendations for future DfMA research. It emphasizes the need for a holistic approach, continued collaboration, and a focus on unexplored aspects of regulatory frameworks and the entire project lifecycle. This study sets a new benchmark in DfMA research by employing a novel mixed-method approach and providing unprecedented insights into the multifaceted role of DfMA in advancing construction industry practices. It serves as a valuable resource for researchers, practitioners, and stakeholders in the construction industry by offering a comprehensive understanding of DfMA’s current state and guiding future research endeavors.

Implementing Universal Design through augmented-reality game-based learning

Technology integration in higher education (HE) provides educators with the opportunity to design stimulating learning environments, especially in design and engineering education (DEE) where it plays a unique role in nurturing creativity, problem-solving and innovation. This study investigates the integration of an augmented reality (AR) educational game in DEE, focusing on the teaching of Design for Manufacturing and Assembly (DfMA) principles. The primary aim of this research is to enhance traditional DfMA teaching and learning (T&L) practices by applying innovative T&L strategies. The resulting AR DfMA game, developed using digital game-based learning, microlearning and collaborative learning techniques, aligns with the Universal Design for Learning framework to create an inclusive learning environment that encourages participation from all students and supports several learning styles.The study tests the individual features designed for personal study opportunities to discover which elements are optimal in that environment, and then on the proposed in-class group components of the AR game, involving 68 participants from the appropriate program, though it is not currently implemented as part of a module. We utilize a mixed methods approach to examine the students’ experience and identify key design features that contribute to an inclusive educational experience. The findings highlight positive student experiences, and preferences for hands-on engagement, multimodal content, and collaborative activities. The AR DfMA game also has the potential to enhance intrinsic motivation and create an active and inclusive learning environment. Challenges and areas for improvement are also discussed.

Methodology for Improving Manufacturing and Assembly of Lightweight Prefab Systems

The increasing adoption of prefabrication in the Global North reflects a response to the urgent demand for safe and affordable housing. This demand is compounded by the necessity to meet contemporary standards for aesthetic quality, structural safety, and energy performance, all within the context of the current climate and safety challenges. Prefabrication, underpinned by the principles of design for manufacturing and assembly (DfMA), offers a pathway toward modernizing construction practices. Specifically, lightweight steel profile technologies, particularly suited for low- and mid-rise buildings, offer an efficient solution to meet these evolving demands. However, to achieve widespread adoption, further optimization is necessary. The reduction of material use, fabrication waste, and production time, alongside cost reduction, will be critical in aligning prefabrication technologies with sustainable development goals. This paper presents an eight-step methodology in which manufacturing and assembling strategies are considered since product development and according to which materials and components are selected, prototyped, and tested to optimize both mechanical and environmental performance. The methodology has been validated through an academic and industrial venture that aimed to optimize a lightweight cold-formed steel volumetric system for housing applications. The study demonstrated to achieve a system that fully met the structural requirements while also minimizing the use of material, waste, and production time. In doing so, this work contributes to a broader effort to modernize construction practices and address the dual imperatives of safety and climate resilience.

Experimental development of lightweight manipulators with improved design cycle time that leverages off-the-shelf robotic arm components.

The growing market for lightweight robots inspires new use-cases, such as collaborative manipulators for human-centered automation. However, widespread adoption faces obstacles due to high R&D costs and longer design cycles, although rapid advances in mechatronic engineering have effectively narrowed the design space to affordable robot components, turning the development of lightweight robots into a component selection and integration challenge. Recognizing this transformation, we demonstrate a practical framework for designing lightweight industrial manipulators using a case-study of indigenously developed 5 Degrees-of-Freedom (DOF) cobot prototype. Our framework incorporates off-the-shelf sensors, actuators, gears, and links for Design for Manufacturing and Assembly (DFMA), along with complete virtual prototyping. The design cycle time is reduced by approximately 40% at the cost of cobot real-time performance deviating within 2.5% of the target metric. Our physical prototype, having repeatability of 0.05mm calculated as per the procedure defined in ISO 9283:1998, validates the cost-effective nature of the framework for creating lightweight manipulators, benefiting robotic startups, R&D organizations, and educational institutes without access to expensive in-house fabrication setups.