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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.

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 communicate a method to perform simultaneous topology optimization of component and support structures considering typical metal additive manufacturing (AM) restrictions and post-print machining requirements.

An integrated topology optimization is proposed using two density fields: one describing the design and another defining the support layout. Using a simplified AM process model, critical overhang angle restrictions are imposed on the design. Through additional load cases and constraints, sufficient stiffness against subtractive machining loads is enforced. In addition, a way to handle non-design regions in an AM setting is introduced.

The proposed approach is found to be effective in producing printable optimized geometries with adequate stiffness against machining loads. It is shown that post-machining requirements can affect optimal support structure layout.

This study uses a simplified AM process model based on geometrical characteristics. A challenge remains to integrate more detailed physical AM process models to have direct control of stress, distortion and overheating.

The presented method can accelerate and enhance the design of high performance parts for AM. The consideration of post-print aspects is expected to reduce the need for design adjustments after optimization.

The developed method is the first to combine AM printability and machining loads in a single topology optimization process. The formulation is general and can be applied to a wide range of performance and manufacturability requirements.

The purpose of this paper is to present the status of the on-going development of the new computerized environment for aircraft synthesis and integrated optimization methods (CEASIOM) and to compare results of different aerodynamic tools. The concurrent design of aircraft is an extremely interdisciplinary activity incorporating simultaneous consideration of complex, tightly coupled systems, functions and requirements. The design task is to achieve an optimal integration of all components into an efficient, robust and reliable aircraft with high performance that can be manufactured with low technical and financial risks, and has an affordable life-cycle cost.

CEASIOM (www.ceasiom.com) is a framework that integrates discipline-specific tools like computer-aided design, mesh generation, computational fluid dynamics (CFD), stability and control analysis and structural analysis, all for the purpose of aircraft conceptual design.

A new CEASIOM version is under development within EU Project AGILE (www.agile-project.eu), by adopting the CPACS XML data-format for representation of all design data pertaining to the aircraft under development.

Results obtained from different methods have been compared and analyzed. Some differences have been observed; however, they are mainly due to the different physical modelizations that are used by each of these methods.

This paper summarizes the current status of the development of the new CEASIOM software, in particular for the following modules: CPACS file visualizer and editor CPACSupdater (Matlab) Automatic unstructured (Euler) & hybrid (RANS) mesh generation by sumo Multi-fidelity CFD solvers: Digital Datcom (Empirical), Tornado (VLM), Edge-Euler & SU2-Euler, Edge-RANS & SU2-RANS Data fusion tool: aerodynamic coefficients fusion from variable fidelity CFD tools above to compile complete aero-table for flight analysis and simulation.

This paper aims to describe the mechanical aspects of unmanned Mothership Plane and Sensing Drones. The presented conceptual system shows the idea and possible way of designing different sizes and objective systems based on experience gained during the SAE Aero Design Competition.

The UAS is based on a SAE Aero Design Competition designed and manufactured Mothership Plane converted to a high endurance platform modified to launch up to six small copters. The process of designing and converting the Mothership is described. The methodology of selecting and planning either the structure or hardware of the drones is presented.

A key finding is that the presented conception of mothership plane deploying in flight a group of small sensing multirotors is achievable. Moreover, the modular build of the system provides the possibility to adapt currently existing unmanned aircrafts to be converted to the described mothership plane.

To conduct flight tests and to study encountered problems. Presentation of the unmanned aerial system (UAS) concept that can be used to scan an area and create 3D maps for Search and Rescue missions as well as agriculture applications.

The paper describes the conceptual approach to design a UAS consisting of the mothership plane and the sensing drones. The paper highlights the potential solutions gained by using such a UAS. The focus is to present a technology and system that can perform real time observations in widespread and difficult to reach areas.

The purpose of this paper is to produce an intelligent technique for modelling machine tool errors caused by the thermal distortion of Computer Numerical Control (CNC) machine tools. A new metaheuristic method, the cuckoo search (CS) algorithm, based on the life of a bird family is proposed to optimize the GMC(1, N) coefficients. It is then used to predict thermal error on a small vertical milling centre based on selected sensors.

A Grey model with convolution integral GMC(1, N) is used to design a thermal prediction model. To enhance the accuracy of the proposed model, the generation coefficients of GMC(1, N) are optimized using a new metaheuristic method, called the CS algorithm.

The results demonstrate good agreement between the experimental and predicted thermal error. It can therefore be concluded that it is possible to optimize a Grey model using the CS algorithm, which can be used to predict the thermal error of a CNC machine tool.

An attempt has been made for the first time to apply CS algorithm for calibrating the GMC(1, N) model. The proposed CS-based Grey model has been validated and compared with particle swarm optimization (PSO) based Grey model. Simulations and comparison show that the CS algorithm outperforms PSO and can act as an alternative optmization algorithm for Grey models that can be used for thermal error compensation.

The safety and reliability of high-speed trains rely on the structural integrity of their components and the dynamic performance of the entire vehicle system. This paper aims to define and substantiate the assessment of the structural integrity and dynamical integrity of high-speed trains in both theory and practice. The key principles and approaches will be proposed, and their applications to high-speed trains in China will be presented.

First, the structural integrity and dynamical integrity of high-speed trains are defined, and their relationship is introduced. Then, the principles for assessing the structural integrity of structural and dynamical components are presented and practical examples of gearboxes and dampers are provided. Finally, the principles and approaches for assessing the dynamical integrity of high-speed trains are presented and a novel operational assessment method is further presented.

Vehicle system dynamics is the core of the proposed framework that provides the loads and vibrations on train components and the dynamic performance of the entire vehicle system. For assessing the structural integrity of structural components, an open-loop analysis considering both normal and abnormal vehicle conditions is needed. For assessing the structural integrity of dynamical components, a closed-loop analysis involving the influence of wear and degradation on vehicle system dynamics is needed. The analysis of vehicle system dynamics should follow the principles of complete objects, conditions and indices. Numerical, experimental and operational approaches should be combined to achieve effective assessments.

The practical applications demonstrate that assessing the structural integrity and dynamical integrity of high-speed trains can support better control of critical defects, better lifespan management of train components and better maintenance decision-making for high-speed trains.

There are over 40 million amputees globally with more than 185,000 Americans losing their limbs every year. For most of the world, prosthetic devices remain too expensive and uncomfortable. This paper aims to outline advancements made by a multidisciplinary research group, interested in advancing the restoration of human motion through accessible lower limb prostheses.

Customization, comfort and functionality are the most important metrics reported by prosthetists and patients. The work of this paper presents the design and manufacturing of a custom made, cost-effective and functional three-dimensional (3D) printed transtibial prosthesis monocoque design. The design of the prosthesis integrates 3D imaging, modelling and optimization techniques coupled with additive manufacturing.

The successful fabrication of a functional monocoque prosthesis through 3D printing indicates the workflow may be a solution to the worldwide accessibility crisis. The digital workflow developed in this work offers great potential for providing prosthetic devices to rural communities, which lack access to skilled prosthetic physicians. The authors found that using the workflow together with 3D printing, this study can create custom monocoque prostheses (Figure 16). These prostheses are comfortable, functional and properly aligned. In comparison with traditional prosthetic devices, the authors slowered the average cost, weight and time of production by 95%, 55% and 95%, respectively.

This novel digital design and manufacturing workflow has the potential to democratize and globally proliferate access to prosthetic devices, which restore the patient’s mobility, quality of life and health. LIMBER’s toolbox can reach places where proper prosthetic and orthotic care is not available. The digital workflow reduces the cost of making custom devices by an order of magnitude, enabling broader reach, faster access and improved comfort. This is particularly important for children who grow quickly and need new devices every few months or years, timely access is both physically and psychologically important.

In this manuscript, the authors show the application of digital design techniques for fabricating prosthetic devices. The proposed workflow implements several advantageous changes and, most importantly, digitally blends the three components of a transtibial prosthesis into a single, 3D printable monocoque device. The development of a novel unibody transtibial device that is properly aligned and adjusted digitally, greatly reduces the number of visits an amputee must make to a clinic to have a certified prosthetist adjust and modify their prosthesis. The authors believe this novel workflow has the potential to ease the worldwide accessibility crisis for prostheses.

The purpose of this paper is to present the development of an optimal design framework for high altitude long endurance solar unmanned aerial vehicle. The proposed solar aircraft design framework provides a simple method to design solar aircraft for users of all levels of experience.

This design framework consists of algorithms and user interfaces for the design of experiments, optimization and mission analysis that includes aerodynamics, performance, solar energy, weight and flight distances.

The proposed sizing method produces the optimal solar aircraft that yields the minimum weight and satisfies the constraints such as the power balance, the night time energy balance and the lift coefficient limit.

The design conditions for the sizing process are given in terms of mission altitudes, flight dates, flight latitudes/longitudes and design factors for the aircraft configuration.

The framework environment is light and easily accessible as it is implemented using open programs without the use of any expensive commercial tools or in-house programs. In addition, this study presents a sizing method for solar aircraft as traditional sizing methods fail to reflect their unique features.

Solar aircraft can be used in place of a satellite and introduce many advantages. The solar aircraft is much cheaper than the conventional satellite, which costs approximately $200-300m. It operates at a closer altitude to the ground and allows for a better visual inspection. It also provides greater flexibility of missions and covers a wider range of applications.

This study presents the implementation of a function that yields optimized flight performance under the given mission conditions, such as climb, cruise and descent for a solar aircraft.

The primary objective of this paper is to show a systematic and methodological approach for the digitalization of critical clinical pathways (CPs) within the healthcare domain.

The methodology entails the integration of service design (SD) and action research (AR) methodologies, characterized by iterative phases that systematically alternate between action and reflective processes, fostering cycles of change and learning. Within this framework, stakeholders are engaged through semi-structured interviews, while the existing and envisioned processes are delineated and represented using BPMN 2.0. These methodological steps emphasize the development of an autonomous, patient-centric web application alongside the implementation of an adaptable and patient-oriented scheduling system. Also, business processes simulation is employed to measure key performance indicators of processes and test for potential improvements. This method is implemented in the context of the CP addressing transient loss of consciousness (TLOC), within a publicly funded hospital setting.

The methodology integrating SD and AR enables the detection of pivotal bottlenecks within diagnostic CPs and proposes optimal corrective measures to ensure uninterrupted patient care, all the while advancing the digitalization of diagnostic CP management. This study contributes to theoretical discussions by emphasizing the criticality of process optimization, the transformative potential of digitalization in healthcare and the paramount importance of user-centric design principles, and offers valuable insights into healthcare management implications.

The study’s relevance lies in its ability to enhance healthcare practices without necessitating disruptive and resource-intensive process overhauls. This pragmatic approach aligns with the imperative for healthcare organizations to improve their operations efficiently and cost-effectively, making the study’s findings relevant.