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The manufacturability of extremely fine porous structures in the SLM process has rarely been investigated, leading to unpredicted manufacturing results and preventing steady medical or industrial application. The research objective is to find out the process limitation and key processing parameters for printing fine porous structures so as to give reference for design and manufacturing planning.

In metallic AM processes, the difficulty of geometric modeling and manufacturing of structures with pore sizes less than 350 μm exists. The manufacturability of porous structures in selective laser melting (SLM) has rarely been investigated, leading to unpredicted manufacturing results and preventing steady medical or industrial application. To solve this problem, a comprehensive experimental study was conducted to benchmark the manufacturability of the SLM process for extremely fine porous structures (less than 350 um and near a limitation of 100 um) and propose a manufacturing result evaluation method. Numerous porous structure samples were printed to help collect critical datasets for manufacturability analysis.

The results show that the SLM process can achieve an extreme fine feature with a diameter of 90 μm in stable process control, and the process parameters with their control strategies as well as the printing process planning have an important impact on the printing results. A statistical analysis reveals the implicit complex relations between the porous structure geometries and the SLM process parameter settings.

It is the first time to investigate the manufacturability of extremely fine porous structures of SLM. The method for manufacturability analysis and printing parameter control of fine porous structure are discussed.

The primary objective of this paper is to illustrate the development of an integrated product development environment using template‐based methodology. This system would thus act as an effective tool to reduce cost by foreseeing manufacturability constraints during concept generation phase. Concurrent engineering approach is applied to product and process development and thus the different phases of manufacturing are integrated together. The developed template system is then used for the design of a prototype using an electric motor.

In this paper, implementation of an integrated design based on templates is presented. The developed system components such as design calculations, component search, machine selection, process template retrieval and cost estimation. These components are integrated to relational databases. These databases contain all information required for integrated product and process development. Concepts used in developing the system are independent of the software used.

By using templates, the time required for new product development is drastically reduced. At the same time incorporating computer‐aided process planning into the system gives the designer a better understanding of the cost implications of the modified design with respect to manufacturing. The major challenge in implementing of such system is that any changes in the manufacturing facility have to be incorporated in the process plans stored. This can be a tedious job but can be overcome by using hybrid process planning approach instead of variant based approach.

The proposed template systems can be further developed to be considered as infrastructure necessary for design within a collaborative engineering environment. Further research and development is necessary for implementation. Though, the result from this case is promising.

The paper proposes the structure necessary for the implementation of a template‐based system. The approach used in the development of the integrated systems could be used by small and mid segment industries which do not have enough resources for costly software upgrading and complex computer technologies. By using templates, the time required for new product development is drastically reduced.

A novel development process aims at finding solutions for lightweight stiffened shell structures and their efficient production. To respect the strong interdependency of structural design and production planning, particularly observed for composite structures, it is of high interest to start considering production effects in early development phases. This integrated approach requires an integrated representation of structure and production. The purpose of this study is to investigate the scope of relevant data and to find a structure for its representation.

The development task is analyzed and a system of so-called solution dimensions is presented, which covers all important aspects of stiffened shell structures and their production. An integrated product data model is developed to cover all of the solution dimensions.

The product data model consists of five coherent partial models. It is explained how these models are defined and how they are connected to each other. An academic example of an aircraft fuselage panel is used to demonstrate the definition process. It is shown how even complex structural concepts are defined systematically.

It is explained how this integrated product data model is used in a software project for the development of aircraft fuselage structures.

The presented approach for the definition and representation of stiffened shell structures enables the developer, e.g. of aircraft fuselage, to respect the crucial criterion of manufacturability from early development phases on. Further, new design approaches, e.g. as inspired by topology optimization, can be considered.

The purpose of this paper is to address the capture and documentation of essential design for manufacture (DFM) pieces of information to make design decisions. Essential manufacturing information is that which can affect the fulfilment of functional requirements and product constraints. The hierarchical structure of the main components for the open architecture‐process planning model (PPM), manufacturing activity model (MAM) and manufacturing resource model (MRM) are discussed The aim of the approach is to define manufacturing knowledge structures and develop a knowledge‐based application for DFM.

This work addresses the capture and documentation of essential DFM pieces of information to make design decisions. Essential manufacturing information is that which can affect the fulfilment of functional requirements and product constraints. The hierarchical structure of the main components for the open architecture‐PPM, MAM and MRM are discussed. The aim of the approach is to define manufacturing knowledge structures and develop a knowledge‐based application for DFM.

This paper gives details of the application framework development by integrating object‐oriented technology and component‐based development. This will help to achieve large‐scale software reuse for manufacturing application development projects. This paper also gives an overview of a computer system for automated concurrent engineering, and more particularly, to a method for the concurrent design of parts, tools and processes.

The workability of this approach was tested in a machine‐tool manufacturing firm and the same has been presented as a case.

This paper aims to present a technical approach to evaluate the quality of textures obtained by an inkjet during binder jetting in 3D printing on a powder bed through contours detection to improve the quality of the surface printed according to the result of the assembly between the inkjet and a granular product.

The manufacturing process is based on the use of computer-aided design and a 3D printer via binder jetting. Image processing measures the edge deviation of a texture on the granular surface with the possibility of implementing a correction in an active assembly through a “design for manufacturing” (DFM) approach. Example application is presented through first tests.

This approach observes a shape alteration of the printed image on a 3D printed product, and the work used the image processing method to improve the model according to the DFM approach.

This paper introduces a solution for improving the texture quality on 3D printed products realized via binder jetting. The DFM approach proposes an active assembly by compensating the print errors in upstream of a product life cycle.

The purpose of this paper is to propose a methodology to estimate manufacturing complexity for both machining and layered manufacturing. The goal is to take into account manufacturing constraints at design stage in order to realize tools (dies and molds) by a combination of a subtractive process (high‐speed machining) and an additive process (selective laser sintering).

Manufacturability indexes are defined and calculated from the tool computer‐aided design (CAD) model, according to geometric, material and specification information. The indexes are divided into two categories: global and local. For local indexes, a decomposition of the tool CAD model is used, based on an octree decomposition algorithm and a map of manufacturing complexity is obtained.

The manufacturability indexes values provide a well‐detailed view of which areas of the tool may advantageously be machined or manufactured by an additive process.

Nowadays, layered manufacturing processes are coming to maturity, but there is still no way to compare these new processes with traditional ones (like machining) at the early design stage. In this paper, a new methodology is proposed to combine additive and subtractive processes, for tooling design and manufacturing. A manufacturability analysis is based on an octree decomposition, with calculation of manufacturing complexity indexes from the tool CAD model.

Among various efforts pursued to produce fuel efficient vehicles, light weight engineering (i.e. the use of low‐density structurally‐efficient materials, the application of advanced manufacturing and joining technologies and the design of highly‐integrated, multi‐functional components/sub‐assemblies) plays a prominent role. In the present work, a multi‐disciplinary design optimization methodology has been presented and subsequently applied to the development of a light composite vehicle door (more specifically, to an inner door panel). The door design has been optimized with respect to its weight while meeting the requirements /constraints pertaining to the structural and NVH performances, crashworthiness, durability and manufacturability. In the optimization procedure, the number and orientation of the composite plies, the local laminate thickness and the shape of different door panel segments (each characterized by a given composite‐lay‐up architecture and uniform ply thicknesses) are used as design variables. The methodology developed in the present work is subsequently used to carry out weight optimization of the front door on Ford Taurus, model year 2001. The emphasis in the present work is placed on highlighting the scientific and engineering issues accompanying multidisciplinary design optimization and less on the outcome of the optimization analysis and the computational resources/architecture needed to support such activity.

Application of the engineering design optimization methods and tools to the design of automotive body‐in‐white (BIW) structural components made of polymer metal hybrid (PMH) materials is considered. Specifically, the use of topology optimization in identifying the optimal initial designs and the use of size and shape optimization techniques in defining the final designs is discussed. The optimization analyses employed were required to account for the fact that the BIW structural PMH component in question may be subjected to different in‐service loads be designed for stiffness, strength or buckling resistance and that it must be manufacturable using conventional injection over‐molding. The paper demonstrates the use of various engineering tools, i.e. a CAD program to create the solid model of the PMH component, a meshing program to ensure mesh matching across the polymer/metal interfaces, a linear‐static analysis based topology optimization tool to generate an initial design, a nonlinear statics‐based size and shape optimization program to obtained the final design and a mold‐filling simulation tool to validate manufacturability of the PMH component.

The purpose of this paper is to present a model linking the role of design engineers to shared team knowledge, enhanced manufacturability, and product development outcomes. New product manufacturability is a quality of the product design that indicates the ease and reliability by which an organization develops products by using its manufacturing and supply chain resources.

The model is tested using a sample of 205 product development projects from firms in the USA and Canada.

The findings of the large‐scale empirical study suggest that by facilitating informing practices among functional specialists, design engineers help translate a functional portrayal of the product in terms of customer attributes, to a form description in terms of engineering characteristics, and then to a fabrication view in terms of manufacturing processes.

New product manufacturability can be a distinctive competency that provides competitive advantage by lowering costs, improving customer value, and speeding products to market.

In contrast to previous research that showed that role changes of design engineers have a narrow impact on development productivity (e.g. improving resource allocation), this paper suggests that these role changes of design engineers have a much broader impact on manufacturability and, through this, improve manufacturing cost, time‐to‐market, and value‐to‐customers.

This paper aims to provide a multi-objective optimization problem in design for manufacturing (DFM) approach for fused deposition modeling (FDM). This method considers the manufacturing criteria and constraints during the design by selecting the best manufacturing parameters to guide the designer and manufacturer in fabrication with FDM.

Topological optimization and bi-objective optimization problems are suggested to complete the DFM approach for design for additive manufacturing (DFAM) to define a product. Topological optimization allows the shape improvement of the product through a material distribution for weight gain based on the desired mechanical behavior. The bi-objective optimization problem plays an important role to evaluate the manufacturability by quantification and optimization of the manufacturing criteria and constraint simultaneously. Actually, it optimizes the production time, required material regarding surface quality and mechanical properties of the product because of two significant parameters as layer thickness and part orientation.

A comprehensive analysis of the existing DFAM approaches illustrates that these approaches are not developed sufficiently in terms of manufacturability evaluation in quantification and optimization levels. There is no approach that investigates the AM criteria and constraints simultaneously. It is necessary to provide a decision-making tool for the designers and manufacturers to lead to better design and manufacturing regarding the different AM characteristics.

To assess the efficiency of this approach, a wheel spindle is considered as a case study which shows how this method is capable to find the best design and manufacturing solutions.

A multi-criteria decision-making approach as the main contribution is developed to analyze FDM technology and its attributes, criteria and drawbacks. It completes the DFAM approach for FDM through a bi-objective optimization problem which deals with finding the best manufacturing parameters by optimizing production time and material mass because of the product mechanical properties and surface roughness.