Although additive manufacturing is a relatively young discipline, the effects that can be achieved with the various additive technologies in terms of efficient product and manufacturing process optimization are of outstanding importance. These processes offer innovative and versatile opportunities for accelerated product design and advanced design and manufacturing process optimization. In addition, the use of nature-based technologies also makes it possible to manufacture components with extreme complexity and internal structures that were very difficult or impossible to produce using conventional methods. Lightweight design and energy savings, also in the product life cycle, can thus be realized with the same stability and load-bearing capacity. This book describes how the potential of additive manufacturing can be used specifically in product development to design highly efficient products. For this purpose, the contents are linked holistically in the sense of development processes of product creation.
Author(s): Roland Lachmayer, Tobias Ehlers, René Bastian Lippert
Publisher: Springer
Year: 2024
Language: English
Pages: 268
Preface to the English edition
Contents
About the Authors
Preface to the English edition
1 Introduction
Bibliography
2 Basics
2.1 Process Chain
2.1.1 Product Design
2.1.2 Pre-Process (Computer Aided Planning)
2.1.3 In-Process (Computer Aided Manufacturing)
2.1.4 Post-Process
2.1.5 Finishing
2.2 Overview of Additive Manufacturing Processes
2.3 Product Creation Process of Additive Manufacturing
Bibliography
3 Component Selection
3.1 SWOT Analysis
3.1.1 Strengths
3.1.2 Weaknesses
3.1.3 Opportunities
3.1.4 Risks
3.2 Potential Assessment
3.2.1 Number of Pieces
3.2.2 Degree of Individualisation
3.2.3 The Complexity of Geometry
3.2.4 Material
3.2.5 Weight
3.2.6 Production Time
3.2.7 Post-Processing
3.2.8 Size
3.2.9 Nesting
3.2.10 Ecological Sustainability
3.3 Component Portfolio Analysis
3.4 Evaluation Catalogue for Component Selection
Bibliography
4 Creative Methods
4.1 Requirement Identification
4.2 Design Goals
4.3 Setting up Functional Structures
4.4 Effect Engineering
4.4.1 Potentials of Effect Engineering
4.4.2 Areas of Application of Effect Engineering
4.4.3 Additive Manufacturing Technologies for Multi-Material Production
4.5 Structure of a Product Architecture
4.5.1 Variation of Product Structure and Shape
4.5.2 Bionics
4.6 Embodiment Design Phase
4.6.1 Basic Design Rules
4.6.2 Design Principles
4.6.3 One-Piece Machine Method
4.6.4 From the Inside to the Outside
4.6.5 From the Outside to the Inside
4.6.6 Configuration from Modular Systems
4.6.7 Development of Model Series
4.6.8 Internal Structures
4.6.9 Structural Optimisation
4.6.10 Graded and Combined Materials
4.7 Development Environment
Bibliography
5 Restrictive Methods
5.1 Design Guidelines
5.2 Concrete Restrictions Using the Example of PBF-LB/M
5.3 Finishing Methods
5.3.1 Mechanical Finishing
5.3.2 Thermal Finishing
5.3.3 Chemical Finishing
5.4 Cost Calculation
Bibliography
6 Machine Setup
6.1 Material
6.1.1 Filaments
6.1.2 Powder
6.1.3 Fluid
6.1.4 Challenges
6.2 Machine Parameters
6.2.1 Fused Layer Modeling
6.2.2 Laser Based Processes
Bibliography
7 Validation and Quality Assurance
7.1 Process Simulation
7.1.1 Inherent Strain Method
7.1.2 Coupled Thermomechanical Simulation
7.1.3 Multi-Scale Approaches
7.1.4 Further Simplifications
7.1.5 Simulation Software
7.1.6 Procedural Model for the Evaluation of the Probability of Statement of Process Simulations
7.2 Process Monitoring and Control
7.2.1 Pyrometry
7.2.2 High-Speed Camera
7.3 Non-Destructive Testing
7.3.1 Computer Tomography (CT)
7.3.2 Optical Coherence Tomography (OCT)
7.3.3 3D Scan Image Correlation Systems
7.3.4 3D High-Speed Image Correlation Systems
7.3.5 Universal Testing Machine
7.3.6 Multiphysics Test Benches
7.4 Destructive Testing
Bibliography
8 Project Examples
8.1 Weight-Reduced Wheel Carrier for a Racing Car
8.2 Function Integration for a Raman Spectroscope
8.3 Weight-Optimised Bicycle Pedal Crank
8.4 Force Flow Adjustment for a Jack Lifter
8.5 Integrated Flow Channels for a Valve
8.6 Computational Design Synthesis of Individualized Implants
8.7 Design for the Sampling of Car Keys
8.8 Net-Shape Geometries for a Reflector
8.9 Multi-Material Design Using the Example of a Heat Exchanger
8.10 Design of a Particle-Damped Motorcycle Triple Clamp with Internal Effects
8.11 Time Savings Through the Use of Additive Repair
8.12 Conclusions and Lessons Learned
8.12.1 Human
8.12.2 Machine
8.12.3 Material
Bibliography
9 Business Models
9.1 Manufacturing Service Provider
9.2 Production Lot Size One and Small Number of Pieces
9.3 Production of Optimised Parts in Larger Quantities
9.4 Integration into a Line Production
9.5 Artistic Design
9.6 Decentralisation of Manufacturing Versus Warehousing
9.7 Additive Repair
9.8 Collaborative Customer
9.9 Handling Technology, Tool and Mould Making
9.10 Rapid Prototyping
Bibliography
10 Is Additive Manufacturing Worth It?
10.1 Environmental Sustainability—Life Cycle Assessment
10.2 Domain-Specific Applications and Economics
10.3 Digitisation and Teaching Concept
Bibliography
Design Catalogue of Additive Manufacturing Processes
Design Catalogue of the Design Guidelines
Glossary
Bibliography
Index
