The past few decades have seen substantial growth in Additive Manufacturing (AM) technologies. However, this growth has mainly been process-driven. The evolution of engineering design to take advantage of the possibilities afforded by AM and to manage the constraints associated with the technology has lagged behind. This paper presents the major opportunities, constraints, and economic considerations for Design for Additive Manufacturing. It explores issues related to design and redesign for direct and indirect AM production. It also highlights key industrial applications, outlines future challenges, and identifies promising directions for research and the exploitation of AM's full potential in industry.

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Design for additive manufacturing: trends, opportunities, considerations, and constraints

Highly oriented carbon fiber–polymer composites via additive manufacturing

Parametric appraisal of mechanical property of fused deposition modelling processed parts

Electrical discharge machining (EDM) is one of the earliest non-traditional machining processes. EDM process is based on thermoelectric energy between the work piece and an electrode. A pulse discharge occurs in a small gap between the work piece and the electrode and removes the unwanted material from the parent metal through melting and vaporising. The electrode and the work piece must have electrical conductivity in order to generate the spark. There are various types of products which can be produced using EDM such as dies and moulds. Parts of aerospace, automotive industry and surgical components can be finished by EDM. This paper reviews the research trends in EDM on ultrasonic vibration, dry EDM machining, EDM with powder additives, EDM in water and modeling technique in predicting EDM performances.

A review on current research trends in electrical discharge machining (EDM)

Design for manufacture and assembly (DFM) has typically meant that designers should tailor their designs to eliminate manufacturing difficulties and minimize manufacturing, assembly, and logistics costs. However, the capabilities of additive manufacturing technologies provide an opportunity to rethink DFM to take advantage of the unique capabilities of these technologies. As mentioned in Chap. 16, several companies are now using AM technologies for production manufacturing. For example, Siemens, Phonak, Widex, and the other hearing aid manufacturers use selective laser sintering and stereolithography machines to produce hearing aid shells; Align Technology uses stereolithography to fabricate molds for producing clear dental braces (“aligners”); and Boeing and its suppliers use polymer powder bed fusion (PBF) to produce ducts and similar parts for F-17 fighter jets. For hearing aids and dental aligners, AM machines enable manufacturing of tens to hundreds of thousands of parts, where each part is uniquely customized based upon person-specific geometric data. In the case of aircraft components, AM technology enables low-volume manufacturing, easy integration of design changes and, at least as importantly, piece part reductions to greatly simplify product assembly.

Design for Additive Manufacturing

Tensile strength, modulus of rupture, and impact resistance were found for different layer orientations of ABS rapid prototype solid models. The samples were fabricated by a Stratasys rapid prototyping machine in five different layer orientations. The 0° orientation where layers were deposited along the length of the samples displayed superior strength and impact resistance over all the other orientations. The anisotropic properties were probably caused by weak interlayer bonding and interlayer porosity.

Effect of Layer Orientation on Mechanical Properties of Rapid Prototyped Samples

Formation of a crater in the workpiece on an electrical discharge machine

Alternative heat treatments for A357-T6 aluminum alloy

Titanium alloy Ti-3Al-2.5V is cheaper to produce and has the potential of improved ductility and formability compared to the Ti-6Al-4V alloy. Various heat treatments were performed on cylindrical tensile test bars in order to optimize the mechanical properties of Ti-3Al-2.5V. The tensile properties of heat-treated Ti-3Al-2.5V were determined at four annealing temperatures with different quenching methods and five different solution treatments and five different aging treatments for varying hours. The samples were tensile tested. The results indicated that optimum properties of high strength and ductility were reached at 926 °C of solution treatment and 480 °C of aging.

R Marloth

Papers

Effect of Layer Orientation on Mechanical Properties of Rapid Prototyped Samples

Formation of a crater in the workpiece on an electrical discharge machine

Alternative heat treatments for A357-T6 aluminum alloy

Effect of Heat Treatments on the Mechanical Properties of Ti-3Al-2.5V Alloy

Failure analysis of K-monel 500 (Ni–Cu–Al alloy) bolts