Abstract
The benefits and drawbacks of Additive Manufacturing Technologies enable designers to think beyond traditional design for manufacture and assembly constraints. AM has unique geometric, material, and customization benefits not provided by other production techniques. Likewise, AM has need for supports, typically produces anisotropic properties, and may require considerable post-processing. These and other benefits and drawbacks of AM have led to an increased emphasis on training designers to Design for Additive Manufacturing. In this chapter, we will revisit some of the concepts from prior chapters and introduce new concepts and ways of thinking to help designers take advantage of AM without falling into design pitfalls.
Access this chapter
Tax calculation will be finalised at checkout
Purchases are for personal use only
Notes
- 1.
Design for manufacturing is typically abbreviated DFM, whereas design for manufacture and assembly is typically abbreviated as DFMA. To avoid confusion with the abbreviation for design for additive manufacturing (DFAM) we have utilized the shorter abbreviation DFM to encompass both design for manufacture and design for assembly.
References
Thompson, M. K., et al. (2016). Design for additive manufacturing: Trends, opportunities, considerations, and constraints. CIRP Annals, 65(2), 737–760.
Susman, G. I. (1992). Integrating design and manufacturing for competitive advantage. New York/Oxford: Oxford University Press.
Bralla, J. (1986). Handbook of product design for manufacturing: A practical guide to low-cost production. New York: McGraw-Hill.
Boothroyd, G., Dewhurst, P., & Knight, W. A. (2001). Product design for manufacture and assembly, revised and expanded. Boca Raton: CRC Press.
Shah, J. J., & Wright, P. K. (2000). Developing theoretical foundations of DFM. In ASME design technical conference.
Rosen, D. W., et al. (2003). The rapid tooling testbed: A distributed design-for-manufacturing system. Rapid Prototyping Journal, 9(3), 122–132.
3D Systems, Inc. (2020). http://www.3dsystems.com
Hague, R. (2006). Unlocking the design potential of rapid manufacturing. In Rapid manufacturing: An industrial revolution for the digital age. Chichester: Wiley.
Mavroidis, C., et al. (2001). Fabrication of non-assembly mechanisms and robotic systems using rapid prototyping. Journal of Mechanical Design, 123(4), 516–524.
Kataria, A., & Rosen, D. W. (2001). Building around inserts: Methods for fabricating complex devices in stereolithography. Rapid Prototyping Journal, 7(5), 253–262.
Binnard, M. (2012). Design by composition for rapid prototyping (Vol. 525). Boston, MA: Springer Science & Business Media.
Patil, L., et al. (2000). Representation of heterogeneous objects in ISO 10303 (STEP). In ASME International Mechanical Engineering Congress and Exposition, Orlando.
Boeing Corp. (2020). http://www.boeing.com
Ulrich, K. T., & Seering, W. P. (1990). Function sharing in mechanical design. Design Studies, 11(4), 223–234.
Nera. (2020). https://bigrep.com/posts/deeper-look_into-the-fully-3d-printed-e-bike-nera/
Gibson, L. J., & Ashby, M. F. (1999). Cellular solids: Structure and properties. Cambridge: Cambridge University Press.
Ashby, M., et al. (2001). Metal foams: A design guide. Applied Mechanics Reviews, 54, B105.
Deshpande, V. S., Fleck, N. A., & Ashby, M. F. (2001). Effective properties of the octet-truss lattice material. Journal of the Mechanics and Physics of Solids, 49(8), 1747–1769.
Wang, A.-J., & McDowell, D. (2003). Optimization of a metal honeycomb sandwich beam-bar subjected to torsion and bending. International Journal of Solids and Structures, 40(9), 2085–2099.
Wang, J., et al. (2003). On the performance of truss panels with Kagome cores. International Journal of Solids and Structures, 40(25), 6981–6988.
Nguyen, J., Park, S.-I., & Rosen, D. (2013). Heuristic optimization method for cellular structure design of light weight components. International Journal of Precision Engineering and Manufacturing, 14(6), 1071–1078.
Lou, S., et al. (2019). Surface texture evaluation of additively manufactured metallic cellular scaffolds for acetabular implants using X-ray computed tomography. Bio-Design and Manufacturing, 2(2), 55–64.
Zhang, A. P., et al. (2012). Rapid fabrication of complex 3D extracellular microenvironments by dynamic optical projection stereolithography. Advanced Materials, 24(31), 4266–4270.
Rosen, D. W. (2007). Computer-aided design for additive manufacturing of cellular structures. Computer-Aided Design and Applications, 4(5), 585–594.
Rose Petal dress. (2020). https://www.dezeen.com/2019/05/09/zac-posen-3d-printed-rose-dress-met-gala/
Black panther. (2020). https://www.dezeen.com/2019/02/27/black-panther-best-costume-design-oscar-3d-printing/
ASTM International. (2018). ISO/ASTM52910-18 Additive manufacturing — Design — Requirements, guidelines and recommendations. West Conshohocken: ASTM International.
ASTM International. (2019). ISO/ASTM52911-2-19 Additive manufacturing — Design — Part 2: Laser-based powder bed fusion of polymers. West Conshohocken: ASTM International.
ASTM International. (2019). ISO/ASTM52911-1-19 Additive manufacturing — Design — Part 1: Laser-based powder bed fusion of metals. West Conshohocken: ASTM International.
Wu, J.J., et al. (2018). 4D printing: History and recent progress. Chinese Journal of Polymer Science, 36(5), 563–575.
Tibbits, S., et al. (2014). 4D Printing and universal transformation. In Material agency. New York: Springer.
Yang, Z., et al. (2006). Thermal and UV shape shifting of surface topography. Journal of the American Chemical Society, 128(4), 1074–1075.
Momeni, F., et al. (2017). A review of 4D printing. Materials & Design, 122, 42–79.
Monzón, M., et al. (2017). 4D printing: Processability and measurement of recovery force in shape memory polymers. The International Journal of Advanced Manufacturing Technology, 89(5–8), 1827–1836.
Jamal, M., et al. (2013). Bio-origami hydrogel scaffolds composed of photocrosslinked PEG bilayers. Advanced Healthcare Materials, 2(8), 1142–1150.
Wu, J., et al. (2016). Multi-shape active composites by 3D printing of digital shape memory polymers. Scientific Reports, 6, 24224.
Zhang, Q., Zhang, K., & Hu, G. (2016). Smart three-dimensional lightweight structure triggered from a thin composite sheet via 3D printing technique. Scientific Reports, 6, 22431.
Gladman, A. S., et al. (2016). Biomimetic 4D printing. Nature Materials, 15(4), 413.
Additive Manufacturing and 3D Printing Research Group, Nottingham University, UK. (2020). https://www.nottingham.ac.uk/research/groups/cfam/
Beaman, J., et al. (2004). Assessment of European research and development in additive. In Subtractive manufacturing, final report from WTEC panel.
Kytannen, J. (2006). Rapid manufacture for the retail industry. In Rapid manufacturing: An industrial revolution for the digital age. Chichester: Wiley.
Ensz, M. T., Storti, D. W., & Ganter, M. A. (1998). Implicit methods for geometry creation. International Journal of Computational Geometry and Applications, 8(05n06), 509–536.
Shapiro, V., & Tsukanov, I. (1999). Meshfree simulation of deforming domains. Computer-Aided Design and Applications, 31(7), 459–471.
Zeid, I. (2004). Mastering CAD/CAM with engineering subscription card. USA: McGraw-Hill.
Rvachev, V. L., et al. (2001). Transfinite interpolation over implicitly defined sets. Computer Aided Geometric Design, 18(3), 195–220.
ASTM International. (2016). ASTM E1325-16, Standard terminology relating to design of experiments. West Conshohocken: ASTM International.
ASTM International. (2017). ASTM E122-17, Standard practice for calculating sample size to estimate, with specified precision, the average for a characteristic of a lot or process. West Conshohocken: ASTM International.
Roy, R. K. (2010). A primer on the Taguchi method. USA (Michigan): Society of Manufacturing Engineers.
Wu, H. (2013). Application of orthogonal experimental design for the automatic software testing. In Applied mechanics and materials. Durnten-Zurich: Trans Tech Publications.
Michell, A. G. M. (1904). LVIII. The limits of economy of material in frame-structures. The London, Edinburgh, and Dublin Philosophical Magazine and Journal of Science, 8(47), 589–597.
Dewhurst, P., & Srithongchai, S. (2005). An investigation of minimum-weight dual-material symmetrically loaded wheels and torsion arms. Journal of Applied Mechanics, 72(2), 196–202.
Baldick, R. (2006). Applied optimization: Formulation and algorithms for engineering systems. Cambridge: Cambridge University Press.
Xia, Q., Wang, M. Y., & Shi, T. (2013). A method for shape and topology optimization of truss-like structure. Structural and Multidisciplinary Optimization, 47(5), 687–697.
Patel, J., & Choi, S.-K. (2012). Classification approach for reliability-based topology optimization using probabilistic neural networks. Structural and Multidisciplinary Optimization, 45(4), 529–543.
Bendsoe, M. P. (1989). Optimal shape design as a material distribution problem. Structural Optimization, 1(4), 193–202.
Sigmund, O. (2001). A 99 line topology optimization code written in Matlab. Structural and Multidisciplinary Optimization, 21(2), 120–127.
Wang, M. Y., Wang, X., & Guo, D. (2003). A level set method for structural topology optimization. Computer Methods in Applied Mechanics and Engineering, 192(1), 227–246.
Leary, M., et al. (2014). Optimal topology for additive manufacture: A method for enabling additive manufacture of support-free optimal structures. Materials & Design, 63, 678–690.
Leary, M. (2019). Design for additive manufacturing. Amsterdam: Elsevier.
Langelaar, M. (2017). An additive manufacturing filter for topology optimization of print-ready designs. Structural and Multidisciplinary Optimization, 55(3), 871–883.
Allaire, G., et al. (2017). Structural optimization under overhang constraints imposed by additive manufacturing technologies. Journal of Computational Physics, 351, 295–328.
Xian, Y., & Rosen, D. W. (2020). Morphable components topology optimization for additive manufacturing. Structural and Multidisciplinary Optimization, 62, 19–39.
Wang, M. Y., & Wang, X. (2004). “Color” level sets: A multi-phase method for structural topology optimization with multiple materials. Computer Methods in Applied Mechanics and Engineering, 193(6–8), 469–496.
Giraldo-Londoño, O., et al. (2020). Multi-material thermomechanical topology optimization with applications to additive manufacturing: Design of main composite part and its support structure. Computer Methods in Applied Mechanics and Engineering, 363, 112812.
Generative design and topology optimization: In-depth look at the two latest design technologies. (2020). https://www.engineering.com/ResourceMain.aspx?resid=826
Autodesk. (2020). https://www.autodesk.com/solutions/generative-design/manufacturing
Oh, S., et al. (2019). Deep generative design: Integration of topology optimization and generative models. Journal of Mechanical Design, 141(11): paper 111405.
Author information
Authors and Affiliations
Rights and permissions
Copyright information
© 2021 Springer Nature Switzerland AG
About this chapter
Cite this chapter
Gibson, I., Rosen, D., Stucker, B., Khorasani, M. (2021). Design for Additive Manufacturing. In: Additive Manufacturing Technologies. Springer, Cham. https://doi.org/10.1007/978-3-030-56127-7_19
Download citation
DOI: https://doi.org/10.1007/978-3-030-56127-7_19
Published:
Publisher Name: Springer, Cham
Print ISBN: 978-3-030-56126-0
Online ISBN: 978-3-030-56127-7
eBook Packages: EngineeringEngineering (R0)