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Materials and Technologies
How additive manufacturing revolutionizes the SMEs' approach to business and product design
Additive Manufacturing for Design– P2
Stefano Lionetti
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Reasons Why
AM (Additive Manufacturing) can offer several benefits in creating prototypes and models, bolstering a product’s value by increasing the efficiency and effectiveness of the design process.
In a SMEs these benefits generally arise in three areas:
• Saving time in the development cycle
• Reducing costs in the development cycle
• Enhancing the final product’s quality and design
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What You Will Learn
• To use the design approach instead of traditional methods
• To choose materials and technologies that prioritize the aspects most relevant to your target application
• To design your products thinking additive rather than in a traditional way
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Thinking Additive
The terminology “design for manufacturing” (DFM) has a general meaning for designers indicating that all the design activities must be focused on optimizing the component in order to minimize problems and costs related to:
• Manufacturing (reduce complexity, machining and scrap material)
• Assembling
• Logistics
Therefore designer should have the awareness of the additive manufacturing processes available and which one will best suit the selected shape and geometry.
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Thinking Additive
In this context, Additive Manufacturing (AM) introduces changes in the DFM definition because of its unique capabilities that are very different from conventional manufacturing.
In particular the main strength points for AM are:
• Geometrical complexity;
• Hierarchical complexity;
• Material complexity;
• Functional complexity;
What are we talking about?
Let’s see this in detail!
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Geometrical Complexity
Since the process is additive, virtually any shape can be realized (with undercuts, hollow structures, internal complex channels, etc.)
An example of complexity is the customization of products or the design complex biomedical parts such as prostheses and medical devices
Resin model (SLA) of a skull (Source: Centro Sviluppo Materiali Spa)
Mould with conformal cooling channels
(Source: Renishaw)
Metallic turbine (Source: Eos gmbh)
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Hierachical complexity
Hierarchical multiscale microstructures can be designed and produced by means of AM, up to macro scale (the component itself).
A complex object with a hierarchical complexity is made of a macro structure which has internally smaller micro structures. An example is a part with an internal complex structure (such as honeycomb like, or trabecular like)
Honeycomb structure (Source: Centro Sviluppo Materiali Spa)
Trabecular structure (Source: www.disanto.com)
Trabecular structure (Source: www.disanto.com)
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Material complexity
Using the additive technology, material is added layer upon layer, so microstructure and material composition can be tailored.
Some technologies allows the manufacturing of multimaterial components.
Multimaterial bike helmet (Source: Stratasys)
Gradient metallic material (Source: NASA JPL)
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Functional complexity
Functional assemblies can be fabricated directly with Additive Manufacturing technology.
Components embedded seamlessy into a watch (Source: voxel8)
Fully functional assembly made of gears and track (Source: Oak Ridge National Lab)
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Traditional VS Additive
Do you still think Traditional Manufacturing could be more effective than Additive Manufacturing?
Let’s see (also with the help of some examples) if you are right!
Think About It
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Traditional VS Additive
AM is a very powerful technology but designer should take into account that this can be «a solution» but it isn’t always the best one. Each case should be analyzed to define which is the most effective manufacturing route: traditional vs. additive.
Source: Deloitte University press
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Traditional VS Additive
The break even point for the selection comes from the cost analysis vs manufacturing volume.
Additive manufacturing costs are linear while conventional manufacturing has a scale effect and unit cost lowers while increasing manufacturing volume.
Obviously AM results most often advantageous for low volumes and very complex geometries.
For example:
• Aerospace components
• Medical applications
• Jewelry and customized consumer goods
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Traditional VS Additive - Example
Analysis of the most effective manufacturing route for a mechanical component used in assemblies for power transmission.
Below is reported the traditional manufacturing sequence usually adopted:
1. Cutting 2. Milling 3. Drilling 4. Milling
5. Milling 6. Milling 7. Drilling 8. Grinding
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Traditional VS Additive - Example
Thinking to a different manufacturing route, the same component can be realized avoiding many of the machining operations required before. Only the drilling and grinding may be maintained due to tolerances required.
1. Cutting 2. Milling 3. Drilling 4. Milling
5. Milling 6. Milling 7. Drilling 8. Grinding
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Traditional VS Additive - Example
The use of additive manufacturing allows the reduction of machining operations only were required for fittings with high tolerances.
Respect to the traditional route, there is also a significative scrap reduction due to the additive methodology.
1. ALM pattern 2. Drilling 3. Grinding
Final component
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Traditional VS Additive - Example
In the table are reported the process differences between the traditional manufacturing and the additive manufacturing.
In this example:
Additive Manufacturing is the most advantageous
Criticality in Machining operations
Criticality in Additive
Manufacturing
Advantages of new process
Geometric complexity
High None No geometric constraints
Machining operations
High Low High quality parts need only few machining for tight tolerances (bores)
Number of parts to be produced
High Low Medium to small batches
can be produced
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Traditional VS Additive
Keep in mind your current products and your manufacturing process.
Do you think you could apply AM as shown in the example?
Think About It
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Material & Technology Selection
In order to utilize AM potentiality in the best way to ensure maximum results in terms of component quality, a specific design chain is needed to move from design specification to final manufacturing of a fully functional part.
Functional specifications
Knowledge of the AM manufacturing process
Design rules Manufacturing sequence optimization Process constraint
AM Machine Finished product
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Material & Technology Selection
What is your need?
• Prototypes
Models
Functional prototypes
Engineering Prototypes
• Patterns
• Tools
• Components
Rapid Prototyping
Rapid Tooling
Additive Manufacturing
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Material & Technology Selection
According to the final application, technology selection is guided from the availability of engineering materials. Direct manufacturing can’t be achieved with every technique due also to technology robustness and process accuracy.
Technology Materials Typical application
Prototypes Tooling Manufacturing
Powder bed Fusion Metals, Polymers X X
Directed Energy Deposition Metals X (repairing) X
Binder Jetting Metals, polymers, foundry
sand X X (Casting moulds) X
Material Jetting Polymers, waxes X X (Casting patterns)
Material Extrusion Polymers X X
Sheet Lamination Metals, paper X
Vat Photopolymerization Photopolymers X
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Material & Technology Selection
Each technology has its own strength points and weaknesses. Qualitative evaluation of the available technologies:
Many other parameters should be considered when selecting a technology:
• speed (important for large quantities of prototypes)
• repeatability
• dimensions of the machine (for large parts)
Ranking goes from one star (Poor) to four stars (Excellent)
Technology Durability Surface finish Details
Powder bed Fusion **** ** ** Directed Energy Deposition **** * *
Binder Jetting *** ** ** Material Jetting ** *** ***
Material Extrusion ** ** ** Sheet Lamination * * *
Vat Photopolymerization ** *** ****
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Component Design
Have you identified some potential AM technologies you are interested into?
Do you have in mind at least one of your products that could be manufactured with one of these technologies?
Now let’s talk about how to redesign it «thinking additive»
Think About It
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Component Design
To obtain a 3D solid object the designer has to model a 3D component using a CAD software. Then the geometry has to be «faceted» approximating surfaces with small triangles (like superficial a mesh). The generated file has the extension .stl and is the standard file for AM machines. According to the quality of the STL file, AM machine will generate a solid model. Poor triangularization generates low quality components.
Original geometry STL (30 triangles)
STL (3000 triangles)
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Component Design
Attention should be focused on CAD tolerances. Since the final object comes out from an approximation (STL file), you should check CAD parameters to obtain the best approximated geometry in terms of shape and number of triangles.
Usually «Chord Height» is the parameter used to modify tolerance: the lower the value the greater the number of triangles. A lower chord height means higher tolerance.
Real shape
Tolerance (chord heigth)
STL Approximation
Tolerance (chord heigth)
Chord heigth reduced
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Component Design
When defining the geometry it is important to know how the process works. The stairstep effect is always present in additive manufacturing. Each technology has its own resolution limit: some machines work with very low slice thicknesses (eg. 0,05 mm or below) but designer should know in advance which technology will be used.
Slicing direction (Z axis)
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Component Design
When designing a component, great attention should be focused on accuracy and detail resolution of the selected technology. Accuracy is affected by:
Z resolution =
Minimum layer thickness
XY resolution =
Minimum laser spot diameter
Layer
thickness
• In plane resolution:
For example in laser based technologies the spot diameter has a fixed value. Small details having dimensions smaller than the laser spot diameter will be «deleted»
• Z axis resolution:
Small particulars has to be compared with the smaller layer thickness used in the selected AM technique. Details smaller than the layer thickness will be lost.
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Component Design
When defining a geometry the designer should take into account also the supporting structures that may be used to build the object. Especially in metal additive machine, supports affect tolerances and surface finish of the component requiring further post processing (e.g. machining, finishing, etc.)
Supports functions/implications:
• used for overhang surfaces (angle > 30°)
• hold the part on the building platform
• hold the part avoiding thermal stresses (particularly for metal additive)
• affect surface roughness
• affect finishing operations and costs
Blade profile
Supporting structures
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Component Design
With the introduction of ALM, component geometries can be very flexible in term of design.
The changes in design can be introduced both on existing components and on new products. In the first case we usually refer to “redesign” while in the latter we are thinking at “optimizing” size and shape of the object in the early stages of the project.
A couple of examples of redesign of mechanical components can help you to better understand advantages of such approach in terms of manufacturing.
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Redesign Of Components – Example n°1
This first example shows the redesign of a mechanical component for the packaging industry. The part was originally made assembling three different parts.
Part n.1 of the assembly (support)
Part n. 3 of the assembly (clamp)
Part n.2 of the assembly (fork)
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Redesign Of Components – Example n°1
The result of the redesign activity produced a single component as shown in the picture:
Results:
• Weight and cost reduction of the part
• Machining reduction
• Elimination of welding
Using the AM process made possible to avoid the need of any mould usually employed to produce a wax pattern.
Expendable pattern made in one piece in Castform PS, a very good material for foundry applications.
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Redesign Of Components – Example n°2
In this second example, it is described the redesign of a multifunctional component for an industrial textile machine.
Many times the assembly operation was very difficult and the final part did not pass quality controls due to misalignments and mounting errors.
The component has several functions and it moves many needles by means of a cam profile.
On the right the initial layout of the component, originally made of a lot of pieces each of them with a specific function.
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Redesign Of Components – Example n°2
The component was redesigned reducing the number of inserts and machining operations.
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Redesign Of Components – Example n°2
The final design of the component was in one piece solution. Every additional part was eliminated or integrated in a single part.
This easy change permitted to reduce significatively the scrap due to quality issues. The part now doesn’t need any further machining rather than surface finishing.
Hollow cilinder integrated in the structure
Hollow cilinder screwed in the structure
Inserts forced in the structure
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Redesign Of Components – Example n°2
The diagram describes the steps of the traditional manufacturing of the multifunctional component:
Disk cut Grinding
Turning (central
bore)
Drilling and
machining internal
path
Machining (inserts)
Turning (stem)
Drilling and
machining (Stem)
Thermal treatments
Final grinding
Assembling and
finishing
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Redesign Of Components – Example n°2
After redesigning the part the manufacturing flow was modified and the machining operations were reduced to the minimum required for the mechanical coupling of the part.
ALM Part manufacturing
Turning (internal stem)
Turning (external stem)
Drilling and machining
(internal Path)
Thermal treatments
Final grinding
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Redesign Of Components – Example n°2
The component was redesigned reducing the number of inserts and machining operations.
The final weight of the part was 410g.
Results:
• Reduced time for production of the component
• Optimized design of the part
• Scrap Reduced
• Weight reduced
• Increased stiffness of the stem
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Traditional VS Additive
Always keeping in mind your current products and your manufacturing process:
Do you think you could redesign your products as shown in the examples?
Could AM be a solution to fasten and reduce costs in your development cycle?
Think About It
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VALUE CHAIN
Additive Manufacturing has a great potential and impact on the manufacturing value chain.
“Traditional” value chain is usually made of a global supplier network.
This deals with the delivery to main production site of primary goods such raw materials, basic parts and components which will be checked, inventoried, processed and assembled to produce a final product.
Then the products are delivered to the different vendors and each of them will distribute the goods to the customers.
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VALUE CHAIN
AM value chain instead is focused on a local supplier network system and a localized manufacturing site.
Differently from traditional value chain, in the localized manufacturing site there’s no need of inventory or stocking components.
All that is needed is the raw material from which can be produced each part.
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Traditional Value Chain Layout
Centralized manufacturing
Supplyer X
Supplyer Y
Supplyer Z
Global Supplyer Network
Finished parts X
Finished parts Y
Finished parts Z
Finished Good A
Finished Good B
Finished Good C
Global Distribution Network
Distributor
Distributor
Distributor
Customer
Customer
Customer
Customer
Customer
Customer
Activities:
• Inventory • Subassemblying • Assemblying
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Additive Manufacturing Value Chain Layout
Localized Manufacturing
Site
Raw material Supplyer
Local Supplyer Network
Finished Good A
Finished Good B
Finished Good C
Localised Distribution
Distributor
Distributor
Distributor
Customer
Customer
Customer
Customer
Customer
Customer
Activities:
• Raw material stock • Additive manufacturing • Assemblying
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Advantages Of The AM Value Chain Layout
Significative reduction of costs is related to transportation and logistics because of the local manufacturing and assembling of the parts.
Transportation of raw materials is cheaper than for finished goods.
Cost of components can be reduced due to the reduction of scrap and the use of only the necessary material.
Moreover, the added costs of the final part can be eliminated due only to intermediate steps of different suppliers/deliverer.
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AM Value Chain Involves New Players
Raw Material (powder, wire)
AM Equipment Design Software
Process/Machine Software
Production
Players in the Additive Manufacturing Value Chain
There are several companies in the market, producing, and supplying raw materials for AM
The sector is rapidly evolving with both emerging companies and consolidated players
Wide offering of software from the market
Usually the process software is not open source and machine vendors have the monopoly
Companies using AM for production, as service to industry
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Traditional Value Chain VS AM Value Chain -
Example
Customized prostheses (for example Hip replacement) are designed before surgery and they fit exactly the anatomy of the patient. Traditional surgery required a lot of manual adjustments and multiple surgical operations.
Anatomy reconstruction
(from CT Scan/MRI)
Modeling (custom implant design)
AM construction of prostheses usually
withTi based material
Surgery
Prostheses Mass
production
Patient fitting, manual shaping
adjustments
CT Scan/MRI For anathomic
analysis
Selection of best fitting prostheses
Surgery
AM value chain
Traditional value chain
Multiple iterations
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Value Chain
Value chain is changing by means of integrated actions:
• Companies are collaborating more and more with AM companies and when this technology is considered a strategic field, AM capabilities are being acquired.
• Niche or strategic production can be developed in an easier way compared to the traditional manufacturing route.
• Companies are introducing AM in their production cycle starting from modifying or replicating existing components using AM technologies.
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Value Chain
Value chain is changing by means of integrated actions:
• Right now, the goal of the major players in the industry is to introduce additive production of complex parts which are difficult to manufacture in the traditional way.
• The capital required to introduce additive technologies reaching the minimum efficient scale for production is lower compared to other technologies and for this reason companies can set up multiple local production sites.
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Value Chain
What about your product development process?
Who are your suppliers, your vendors, your customers, etc.?
Do you think Additive Manufacturing could have a great potential and impact on the manufacturing value chain of your SME?
Think About It
Thank you for your attention
www.designforenterprises.eu #Design4Enterprises
Materials and Technologies
Additive Manufacturing for Design– P2
