Design for Additive Manufacturing

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. The content Provides a comprehensive overview of the rapidly expanding field of additive manufacturing Presents a holistic development process for designing additively manufactured structural parts Extensive practical examples that illustrate the design for additive manufacturing 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