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Non-uniform rational B-splines (NURBSs) are the de facto standard for representing objects in computer-aided design (CAD). The purpose of this paper is to discuss how to stick to this standard in all phases of the additive manufacturing (AM) workflow, from the CAD object to the final G-code, bypassing unnecessary polygonal approximations.

The authors use a commercial CAD system (Rhino3D along with its programming environment Grasshopper) for direct slicing of the model, offset generation and trimming. Circular arcs are represented as quadratic NURBSs and free-form geometry as quadratic or cubic polynomial B-splines. Therefore, circular arcs are directly expressible as G2/G3 G-code commands, whereas free-form paths are rewritten as a succession of cubic Bézier curves, thereby admitting exact translation into G5 commands, available in firmware for AM controllers, such as Marlin.

Experimental results of this paper confirm a considerable improvement in quality over the standard AM workflow, consisting of an initial polygonization of the object (e.g. via standard tessellation language), slicing this polygonal approximation, offsetting the polygonal sections and, finally, generating G-code made up of polyline trajectories (G1 commands).

A streamlined AM workflow is obtained, with a seamless transfer from the initial CAD description to the final G-code. By adhering to the NURBS standard at all steps, the authors avoid multiple representations and associated errors resulting from approximations.

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.

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.

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.

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.

The paper aims to raise awareness in the industry of design automation tools, especially in early design phases, by demonstrating along a case study the seamless integration of a prototypically implemented optimization, supporting design space exploration in the early design phase and an in operational use product configurator, supporting the drafting and detailing of the solution predominantly in the later design phase.

Based on the comparison of modeled as-is and to-be processes of ascent assembly designs with and without design automation tools, an automation roadmap is developed. Using qualitative and quantitative assessments, the potentials and benefits, as well as acceptance and usage aspects, are evaluated.

Engineers tend to consider design automation for routine tasks. Yet, prototypical implementations support the communication and identification of the potential for the early stages of the design process to explore solution spaces. In this context, choosing from and interactively working with automatically generated alternative solutions emerged as a particular focus. Translators, enabling automatic downstream propagation of changes and thus ensuring consistency as to change management were also evaluated to be of major value.

A systematic validation of design automation in design practice is presented. For generalization, more case studies are needed. Further, the derivation of appropriate metrics needs to be investigated to normalize validation of design automation in future research.

Integration of design automation in early design phases has great potential for reducing costs in the market launch. Prototypical implementations are an important ingredient for potential evaluation of actual usage and acceptance before implementing a live system.

There is a lack of systematic validation of design automation tools supporting early design phases. In this context, this work contributes a systematically validated industrial case study. Early design-phases-support technology transfer is important because of high leverage potential.

The purpose of this research is to support the customization ability for industrial house building companies striving to offer individualized products but with a strategy which includes a production facility. This is accomplished by analyzing the as-is state in terms of existing engineering assets and by proposing a to-be state using the design platform and product lifecycle management (PLM) support.

This study is based on design research methodology and collected data are in-depth interviews, document reviews and workshops and method development. The theoretical baseline is product platforms and the design platform.

The analysis showed that despite use of a platform, inherent assets are disorganized. Still, the identified object-based engineering assets were possible to include in a conceptual proposal for better management, both in the process and product view, using an asset relationship matrix and a PLM system.

The results should be applicable for industrial house building and off-site construction companies and offers an approach to identify and manage their assets and platforms which are crucial to stay competitive.

Previous research on design platforms has focused on engineer-to-order companies within the mechanical industry. The contribution of this paper lies in the application and support of the design platform for industrial house building and the introduction of PLM system support.

This study aims to provide a comprehensive overview of the current state of the art in powder bed fusion (PBF) techniques for additive manufacturing of multiple materials. It reviews the emerging technologies in PBF multimaterial printing and summarizes the latest simulation approaches for modeling them. The topic of “multimaterial PBF techniques” is still very new, undeveloped, and of interest to academia and industry on many levels.

This is a review paper. The study approach was to carefully search for and investigate notable works and peer-reviewed publications concerning multimaterial three-dimensional printing using PBF techniques. The current methodologies, as well as their advantages and disadvantages, are cross-compared through a systematic review.

The results show that the development of multimaterial PBF techniques is still in its infancy as many fundamental “research” questions have yet to be addressed before production. Experimentation has many limitations and is costly; therefore, modeling and simulation can be very helpful and is, of course, possible; however, it is heavily dependent on the material data and computational power, so it needs further development in future studies.

This work investigates the multimaterial PBF techniques and discusses the novel printing methods with practical examples. Our literature survey revealed that the number of accounts on the predictive modeling of stresses and optimizing laser scan strategies in multimaterial PBF is low with a (very) limited range of applications. To facilitate future developments in this direction, the key information of the simulation efforts and the state-of-the-art computational models of multimaterial PBF are provided.

The purpose of this paper is to establish a chair-side design and production method for a tooth-supported fixed implant guide and to evaluate its accuracy.

Three-dimensional (3D) data of the alveolar ridge, adjacent teeth and antagonistic teeth were acquired from models of the edentulous area of 30 patients. The implant guides were then constructed using self-developed computer-aided design software and chair-side fused deposition modelling 3D-printing and positioned on a dental model. A model scanner was used to acquire 3D data of the positioned implant guides, and the overall error was then evaluated.

The overall error was 0.599 ± 0.146 mm (n = 30). One-way ANOVA revealed no statistical differences among the 30 implant guides. The gap between the occlusal surface of the teeth covering and the tissue surface of the implant guide was measured. The maximum gap after positioning of the implant guide was 0.341 mm (mean, 0.179 ± 0.019 mm). The implanted axes of the printed implant guide and designed guide were compared in terms of overall, lateral and angular error, which were 0.104 ± 0.004 mm, 0.097 ± 0.003 mm, and 2.053° ± 0.017°, respectively.

The results of this study demonstrated that the accuracy of a new chair-side tooth-supported fixed implant guide can satisfy clinical requirements.

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.

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.

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.

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.

The purpose of this paper is to exploit a database of pre-existing designs to accelerate parametric optimization of antenna structures is investigated.

The usefulness of pre-existing designs for rapid design of antennas is investigated. The proposed approach exploits the database existing antenna base designs to determine a good starting point for structure optimization and its response sensitivities. The considered method is suitable for handling computationally expensive models, which are evaluated using full-wave electromagnetic (EM) simulations. Numerical case studies are provided demonstrating the feasibility of the framework for the design of real-world structures.

The use of pre-existing designs enables rapid identification of a good starting point for antenna optimization and speeds-up estimation of the structure response sensitivities. The base designs can be arranged into subsets (simplexes) in the objective space and used to represent the target vector, i.e. the starting point for structure design. The base closest base point w.r.t. the initial design can be used to initialize Jacobian for local optimization. Moreover, local optimization costs can be reduced through the use of Broyden formula for Jacobian updates in consecutive iterations.

The study investigates the possibility of reusing pre-existing designs for the acceleration of antenna optimization. The proposed technique enables the identification of a good starting point and reduces the number of expensive EM simulations required to obtain the final design.

The proposed design framework proved to be useful for the identification of good initial design and rapid optimization of modern antennas. Identification of the starting point for the design of such structures is extremely challenging when using conventional methods involving parametric studies or repetitive local optimizations. The presented methodology proved to be a useful design and geometry scaling tool when previously obtained designs are available for the same antenna structure.

A novel framework for expedited antenna optimization with an iterative prediction-correction scheme is proposed. The methodology is comprehensively validated using three real-world antenna structures: narrow-band, dual-band and wideband, optimized under various design scenarios.

The keystone of the proposed approach is to reuse designs pre-optimized for various sets of performance specifications and to encode them into metamodels that render good initial designs, as well as an initial estimate of the antenna response sensitivities. Subsequent design refinement is realized using an iterative prediction-correction loop accommodating the discrepancies between the actual and target design specifications.

The presented framework is capable of yielding optimized antenna designs at the cost of just a few full-wave electromagnetic simulations. The practical importance of the iterative correction procedure has been corroborated by benchmarking against gradient-only refinement. It has been found that the incorporation of problem-specific knowledge into the optimization framework greatly facilitates parameter adjustment and improves its reliability.

The proposed approach can be a viable tool for antenna optimization whenever a certain number of previously obtained designs are available or the designer finds the initial effort of their gathering justifiable by intended re-use of the procedure. The future work will incorporate response features technology for improving the accuracy of the initial approximation of antenna response sensitivities.

The proposed optimization framework has been proved to be a viable tool for cost-efficient and reliable antenna optimization. To the knowledge, this approach to antenna optimization goes beyond the capabilities of available methods, especially in terms of efficient utilization of the existing knowledge, thus enabling reliable parameter tuning over broad ranges of both operating conditions and material parameters of the structure of interest.

This paper presents an experimental investigation in establishing the relationship between FDM process parameters and tensile strength of polycarbonate (PC) samples using the I-Optimal design.

I-optimal design methodology is used to plan the experiments by means of Minitab-17.1 software. Samples are manufactured using Stratsys FDM 400mc and tested as per ISO standards. Additionally, an artificial neural network model was developed and compared to the regression model in order to select an appropriate model for optimisation. Finally, the genetic algorithm (GA) solver is executed for improvement of tensile strength of FDM built PC components.

This study demonstrates that the selected process parameters (raster angle, raster to raster air gap, build orientation about Y axis and the number of contours) had significant effect on tensile strength with raster angle being the most influential factor. Increasing the build orientation about Y axis produced specimens with compact structures that resulted in improved fracture resistance.

The fitted regression model has a p-value less than 0.05 which suggests that the model terms significantly represent the tensile strength of PC samples. Further, from the normal probability plot it was found that the residuals follow a straight line, thus the developed model provides adequate predictions. Furthermore, from the validation runs, a close agreement between the predicted and actual values was seen along the reference line which further supports satisfactory model predictions.

This study successfully investigated the effects of the selected process parameters - raster angle, raster to raster air gap, build orientation about Y axis and the number of contours - on tensile strength of PC samples utilising the I-optimal design and ANOVA. In addition, for prediction of the part strength, regression and ANN models were developed. The selected ANN model was optimised using the GA-solver for determination of optimal parameter settings.

The proposed ANN-GA approach is more appropriate to establish the non-linear relationship between the selected process parameters and tensile strength. Further, the proposed ANN-GA methodology can assist in manufacture of various industrial products with Nylon, polyethylene terephthalate glycol (PETG) and PET as new 3DP materials.