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Implementation of interdisciplinary student teams in design education for additive manufacturing
(2018)
Additive manufacturing (AM) technologies are becoming increasingly popular in all areas of product development. Therefore, it is imperative that students be taught Design for AM. However, due to the rapid development of new methods and materials for AM, it does not make sense to only teach particular design guidelines, as these can quickly become obsolete. Rather, students should acquire the competence to develop guidelines themselves, that take into account the current state of the art. Thus, they will be able to react to changing processes and new materials
in the future. In order to convey the independent development of design guidelines for additive manufacturing by students, a new concept was developed, which is presented in this contribution. In this process, the learning goal is worked out by a group of students on the basis of a practical
task. The group consists of an interdisciplinary team in order to combine different competencies and to provide different perspectives on the task. A case study will show the design and manufacture of a miniature aircraft using Fused Layer Modelling. The aim of the development is above all the design for additive manufacturing. In addition, a low use of resources in combination with lightweight construction should be achieved. In the implementation of the task, the students are confronted with challenging aerodynamic design of wings as well as with the economic evaluation of the development process. An examination of the level of knowledge before and after the case study examines the learning success.
Various methods of Digital Manufacturing (DM) have been available for the manufacturing of physical architectural models for several years. This paper highlights the advantages of 3D printing for digital manufacturing of detailed architectural models. In particular, the representation of architectural details and textures is treated. Furthermore, two new methods are being developed in order to improve the conditions for the application of digital manufacturing of architectural models.
Besides of conventional CAD systems, new, cloudbased CAD systems have also been available for some years. These CAD systems designed according to the principle of software as a service (SaaS) differ in some important features from the conventional CAD systems. Thus, these CAD systems are operated via a browser and it is not necessary to install the software on a computer. The CAD-data is stored in the cloud and not on a local computer or central server. This new approach should also facilitate the sharing and management of data. Finally, many of these new CAD systems are available as freeware for education purposes, so the universities can save license costs. The chances and risks of cloud-based systems will first be analyzed in this paper. Then two leading cloud-based CAD systems will be researched. During the process, the technical performance range these new systems offer for the product development will be initially checked and reviewed. For this purpose, various criteria are worked out and the CAD software is evaluated using these criteria. In addition, the criteria are weighted by their importance for design education. This allows one to conclude which capabilities the different CAD system offers for use in education.
Wir haben die erste „Eiserne Hand“ des Götz von Berlichingen mit 3D-Computer-Aided Design rekonstruiert und über einen Multimaterial-3D-Drucker ausgedruckt. Dabei ließ sich feststellen, dass die 500 Jahre alte Technik keinesfalls veraltet ist: Das Innenleben der „Eisernen Hand“ ist ausgefeilter als bisher angenommen. Sie könnte sogar spannende Impulse für die Entwicklung neuer künstlicher Handprothesen liefern.
Fusion 360 – kurz und bündig
(2019)
Dieses Lehrbuch ermöglicht dem Anfänger in der 3D-Modellierung einen schnellen Einstieg in die Arbeit mit dem cloudbasierten CAD-System Autodesk® Fusion 360™. Der Schwerpunkt liegt dabei auf den grundlegenden Funktionen zur Modellierung von Einzelteilen und Produkten, sowie in der Erstellung von einfachen technischen Zeichnungen. Dabei werden bei jedem Schritt die besonderen Anforderungen an eine 3D-Druck-gerechte Gestaltung erläutert und umgesetzt. Somit ist das Ergebnis dieser "Schritt für Schritt"-Anleitung die vollständige Modellierung eines Miniatur-Automobils, das am 3D-Drucker in ein reales Modell umgesetzt werden kann. Das didaktische Konzept ist so ausgelegt, dass alle Schritte für ein Selbststudium geeignet sind.
The additive manufacturing processes have developed significantly in recent years. Currently, new generative processes are coming onto the market. Likewise, the number of available materials that can be processed using additive processes is steadily increasing. Therefore, an important task is to integrate these new processes and materials into the university education of engineers. Due to the rapid change and the constant development in the field of additive manufacturing, a pure transfer of knowledge is not expedient, because this obsolete very quickly. Rather, the students should be enabled to use their skills in such a way that they can always handle new technologies and materials independently and meaningfully.
In this paper, therefore, a new course is developed in which the students largely independently work with additive manufacturing processes. For this purpose, teams of four to five students from different technical programs are formed. The teams have the task of developing and manufacturing a product using additive processes. The goal is to create a powerful product by taking into account the optimization of costs and use of resources.
As an example, the development and additive manufacturing of an ornithopter (aircraft that flies by flapping its wings) will be presented in this contribution. The students have to analyze and optimize the mechanics and aerodynamics of the aircraft. In addition, the rules for production-oriented design must be determined and applied. Further more, they should assess the costs and material consumption during development and production.
This contribution shows how the students have achieved the different learning outcomes. In addition, it becomes clear how the students independently acquired and applied their knowledge in development, design and additive manufacturing. Also, it will be demonstrated how much time the students spent on learning the different technologies.
The development of new processes and materials for additive manufacturing is currently progressing rapidly. In order to use the advantages of additive manufacturing, however, product development and design must also be adapted to these new processes. Therefore it is suitable to use structural optimization. To achieve the best results in lightweight design, it is important to have an approach that reduces the volume in the unloaded regions and considers the restrictions and characteristics of the additive manufacturing process. In this contribution, a case study using a humanoid robot is presented. Thus, the pelvis module of a humanoid robot is optimized regarding its weight and stiffness. Furthermore, an integrated design is implemented in order to reduce the number of parts and the screw connections. The manufacturing uses a new aluminum-based material that has been specially developed for use in additive manufacturing and lightweight construction. For the additive manufacturing by means of the Selective Laser Melting (SLM) process, different restrictions and the assembly concepts of the humanoid robot have to be taken into account. These restrictions have to be considered in the setting of the individual parameters and target functions of the structural optimization. As a result, a framework is presented that shows the steps of the redesign and the optimization of the pelvis module. In order to achieve high accuracy with the product, the redesign of the pelvis module is demonstrated with regard to mechanical and thermal postprocessing. Finally, the redesigned part and the different assembly concepts are compared to analyze the economic and technical effects of the optimization.