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Open Access
Article
Publication date: 14 October 2021

Anton Wiberg, Johan Persson and Johan Ölvander

The purpose of this paper is to present a Design for Additive Manufacturing (DfAM) methodology that connects several methods, from geometrical design to post-process…

Abstract

Purpose

The purpose of this paper is to present a Design for Additive Manufacturing (DfAM) methodology that connects several methods, from geometrical design to post-process selection, into a common optimisation framework.

Design/methodology/approach

A design methodology is formulated and tested in a case study. The outcome of the case study is analysed by comparing the obtained results with alternative designs achieved by using other design methods. The design process in the case study and the potential of the method to be used in different settings are also discussed. Finally, the work is concluded by stating the main contribution of the paper and highlighting where further research is needed.

Findings

The proposed method is implemented in a novel framework which is applied to a physical component in the case study. The component is a structural aircraft part that was designed to minimise weight while respecting several static and fatigue structural load cases. An addition goal is to minimise the manufacturing cost. Designs optimised for manufacturing by two different AM machines (EOS M400 and Arcam Q20+), with and without post-processing (centrifugal finishing) are considered. The designs achieved in this study show a significant reduction in both weight and cost compared to one AM manufactured geometry designed using more conventional methods and one design milled in aluminium.

Originality/value

The method in this paper allows for the holistic design and optimisation of components while considering manufacturability, cost and component functionality. Within the same framework, designs optimised for different setups of AM machines and post-processing can be automatically evaluated without any additional manual work.

Details

Rapid Prototyping Journal, vol. 27 no. 11
Type: Research Article
ISSN: 1355-2546

Keywords

Open Access
Article
Publication date: 6 August 2019

Anton Wiberg, Johan Persson and Johan Ölvander

This paper aims to review recent research in design for additive manufacturing (DfAM), including additive manufacturing (AM) terminology, trends, methods, classification…

12177

Abstract

Purpose

This 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/approach

The 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.

Findings

Existing 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/value

The 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.

Details

Rapid Prototyping Journal, vol. 25 no. 6
Type: Research Article
ISSN: 1355-2546

Keywords

Article
Publication date: 31 January 2022

Aliakbar Kamari, Bartlomiej Marek Kotula and Carl Peter Leslie Schultz

A robust method in environmental load assessment of buildings is urgently required to reduce the environmental burden of the construction industry. While the industry…

482

Abstract

Purpose

A robust method in environmental load assessment of buildings is urgently required to reduce the environmental burden of the construction industry. While the industry utilizes the life cycle assessment (LCA) method to assess environmental impacts of detailed designs, the implementation of changes at that late stage of development is often expensive and undesirable. On the other hand, during the early design stages, the LCA method is severely limited by the lack of information available, e.g., uncertainty about final materials to be used. This research study investigates how building information modeling (BIM) can facilitate LCA analysis at an early design stage.

Design/methodology/approach

A literature review is conducted to establish a framework for BIM and LCA integration, which creates the foundation for the development of a new BIM-based LCA tool. The tool is empirically evaluated on a large case study of a residential building in Denmark.

Findings

Case study results show that the new tool facilitates decision-making in an integrated design process, providing reliable LCA results on an early stage model, while avoiding intermediate manual input by the end user in contrast to other commercial LCA tools.

Originality/value

A first prototype of a BIM-based tool is demonstrated, which allows professionals, small architectural companies, students and researchers to calculate the environmental loads of the building in the early design stage in an automated, transparent and time-saving manner.

Details

Smart and Sustainable Built Environment, vol. 11 no. 2
Type: Research Article
ISSN: 2046-6099

Keywords

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