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

Fused deposition modeling (FDM) is one of the most popular additive manufacturing technologies for various engineering applications. FDM process has been introduced commercially in early 1990s by Stratasys Inc., USA. The quality of FDM processed parts mainly depends on careful selection of process variables. Thus, identification of the FDM process parameters that significantly affect the quality of FDM processed parts is important. In recent years, researchers have explored a number of ways to improve the mechanical properties and part quality using various experimental design techniques and concepts. This article aims to review the research carried out so far in determining and optimizing the process parameters of the FDM process. Several statistical designs of experiments and optimization techniques used for the determination of optimum process parameters have been examined. The trends for future FDM research in this area are described.

https://www.aim.shu.edu.cn/CN/article/downloadArticleFile.do?attachType=PDF&id=122

Optimization of fused deposition modeling process parameters: a review of current research and future prospects

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

The objective of this research was to find the best combination of factor levels that minimized the surface roughness of prototyped samples from Fused Deposition Modeling (FDM). Two sets of experiments were conducted for that purpose; a two-level three-factor full factorial experiment and a three-level two-factor full factorial experiment. The parameters chosen for this research were model temperature, layer thickness and part fill style. The results obtained from both experiments were compared and analyzed in order to determine the best combination of factors that minimized the surface roughness of the specimens. The significant factors, their interactions and the optimum setting are presented in this paper

Improvement of Surface Roughness on ABS 400 Polymer Using Design of Experiments (DOE)

Rapid prototyping turns a three-dimensional CAD drawing into an actual part that can be tested for form, fit, and function. Therefore, accuracy of the prototype is important. The goal of this research was to improve in-plane dimensional accuracy for the Stratasys FDM 1650 rapid prototyping machine. The CHRISTMAS-TREE™ test procedure developed by 3D Systems, Inc., was used to arrive at a new shrinkage compensation factor (SCF) for the Stratasys machine. It was found that an SCF of 1.010 will produce a 53% reduction in mean error of the dimensions. More test procedures could be implemented to further refine accuracy. © 1999 John Wiley & Sons, Inc. Comput Appl Eng Educ 7: 186–195, 1999

Calculation of shrinkage compensation factors for rapid prototyping (FDM 1650)

The objective of this research was to find the best combination of factor levels that minimized the surface roughness of prototyped samples from Fused Deposition Modeling (FDM). Two sets of experiments were conducted for that purpose; a two-level three-factor full factorial experiment and a three-level two-factor full factorial experiment. The parameters chosen for this research were model temperature, layer thickness and part fill style. The results obtained from both experiments were compared and analyzed in order to determine the best combination of factors that minimized the surface roughness of the specimens. The significant factors, their interactions and the optimum setting are presented in this paper.

Improvement of surface roughness on abs 400 polymer materials using design of experiments (DOE)

This book presents fused deposition modeling (FDM) which is an additive manufacturing (AM) process to fabricate 3D parts from a build-up of 2D layers 

Rafiq Noorani

Papers

Effect of Layer Orientation on Mechanical Properties of Rapid Prototyped Samples

Improvement of Surface Roughness on ABS 400 Polymer Using Design of Experiments (DOE)

Calculation of shrinkage compensation factors for rapid prototyping (FDM 1650)

Improvement of surface roughness on abs 400 polymer materials using design of experiments (DOE)

The Effect of Layer Orientation on the Fatigue Behavior of 3D Printed PLA Samples