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Plastics are used today in many areas of the automotive, aerospace and mechanical engineering industries due to their lightweight potential and ease of processing. Additive manufacturing is applied more and more frequently, as it offers a high degree of design freedom and eliminates the need for complex tools. However, the application of additively manufactured components made of plastics have so far been limited due to their comparatively low strength. For this reason, processes that offer additional reinforcement of the plastic matrix using fibers made of high-strength materials have been developed. However, these components represent a composite of different materials produced on the basis of fossil raw materials, which are difficult to recycle and generally not biodegradable.
Therefore, this paper will explore the potential for new composite materials whose matrix consists of a bio-based plastic. In this investigation, it is assumed that the matrix is reinforced with a fibrous material made of natural fiber to significantly increase the strength. This potential material should offer a lightweight yet strong structure and be biodegradable after use under controlled conditions. Therefore, the state of the art in the use of bio-based materials in 3D printing is first presented. In order to determine the economic boundary conditions, the growth potentials for bio-based materials are analyzed. Also, the recycling prospects for bio-based plastics will also be highlighted. The greenhouse gas emissions and land use to be expected when using bio-based materials are also estimated. Finally, the degradability of the composites is discussed.
In addition to traditional methods in product development, the increasing availability of additive manufacturing AM technologies offer new opportunities in product development processes today. This contribution explores several ways in which AM can productively be used in education. New to this approach is amongst others that the students assemble and install the 3D-printers themselves. In two case studies is demonstrated how students in design education are able to autonomously research and realize technical possibilities and limitations of AM technologies, as well as economic constraints.
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.
The integration of additive manufacturing processes into the teaching of students is an important prerequisite for the further dissemination of this new technology. In this context, the DfAM is of particular importance. For this reason, this paper presents an approach in which a connection is made between methodical product development and practical implementation by AM. Using a model racing car as an example, students independently develop significant improvements of particular assemblies. A final evaluation shows that the students have significantly improved their skills and competencies.
Today the methods of numerical simulation of sheet metal forming offer a great diversity of possibilities for optimization in product development and in process design. However, the results from simulation are only available as virtual models. Because there are any forming tools available during the early stages of product development, physical models that could serve to represent the virtual results are therefore lacking. Physical 3D-models can be created using 3D-printing and serve as an illustration and present a better understanding of the simulation results. In this way, the results from the simulation can be made more “comprehensible” within a development team. This paper presents the possibilities of 3D-colour printing with particular consideration of the requirements regarding the implementation of sheet metal forming simulation. Using concrete examples of sheet metal forming, the manufacturing of 3D colour models will be expounded upon on the basis of simulation results.
The present-day methods of numerical simulation offer a great variety of options for optimizing metal forming processes. Although it is possible to simulate complex forming processes, the results are typically available only as 2D projections on screens. Some forming processes have reached a level of complexity beyond the level of spatial sense, which makes it necessary to use physical 3D representations to develop a deeper understanding of the material flow, microstructural processes, process and design limits, or to design the required tooling. Physical 3D models can be produced in a short amount of time using 3D printing, and indexed with a wide range of colors. In this paper, the additive manufacturing of 3D color models based on simulation results are explored by means of examples from metal forming. Different 3D-printing processes are compared on the basis of quality as well as technical and economic criteria. Other examples from the fields joining by upset-bulging of tubes and microstructure simulation are also analyzed. This paper discusses the possibilities offered by the rapid progress and wide availability of 3D printers for the design and optimization of complex metal forming processes.
As a reaction to the increasing market dynamics and complex requirements, today’s products need to be developed quickly and customized to the customer’s individual needs. In the past, CAD systems are mainly used to visualize the model that the product designer creates. Generative Design shifts the task of the CAD program by actively participating in the shaping process. This results in more design options and the complexity of the shapes and geometries increases significantly. This potential can be optimally exploited through the combination of Generative Design with Additive Manufacturing (AM). Artificial intelligence and the input of target parameters generate geometries, for example, by creating material for stressed areas, which in turn develops biomorphic shapes and thus significantly reduces the consumption of resources. This contribution aims at the evaluation of existing applications in CAD systems for generative design. Special attention is paid to the requirements in design education and easy access for students. For this purpose, three representative CAD systems are selected and analyzed with the help of a comprehensive example of mass reduction. The aim is to perform an individual result analysis in order to assess the application based on various criteria. By using different materials, the influence of the material for the generation is investigated by comparing the material distribution. By comparing the generated models, differences of the CAD systems can be identified and possible fields of application can be presented. By specifying the manufacturing parameters for the generation of the models, the feasibility of AM can be guaranteed without having to modify the results. The physical implementation of the example by means of Fused Deposition Modeling demonstrates this in an exemplary way and examines the interface of the Generative Design and AM. The results of this contribution will enable an evaluation of the different CAD systems for Generative Design according to technical, visual and economic aspects.
Additive manufacturing enables the production of lightweight and resilient components with extensive design freedom. In the low-cost sector, material extrusion (e.g. Fused Deposition Modeling - FDM) has been the main method used to date. Thus, robust 3D printers and inexpensive 3D materials (polymer filaments) can be used. However, the printing times for FDM are very long and the quality of the dimensions and surfaces is limited. Recently, new processes from the field of Vat polymerization have entered the market. For example, masked stereolithography (mSLA) offers a significant improvement in component quality and build speed through the use of resins and large-area curing at still reasonable costs. Currently, there is only limited knowledge available on the optimal design of components using this young process. In this contribution, design guidelines are developed to determine the possibilities and limitations of mSLA from a design point of view. For this purpose, a number of test geometries are designed and investigated to obtain systematic insights into important design features, such as wall thickness, grooves and holes. In addition, typical problems in additive manufacturing, such as the design of overhangs and fits or the hollowing of components, are investigated. The evaluation of practical 3D printing tests thus provides important parameters that can be transferred to design guidelines of components for additive manufacturing using mSLA.
Various Rapid Prototyping methods have been available for the production of physical architectural models for a few years. This paper highlights in particular the advantages of 3D printing for the production of detailed architectural models. In addition, the current challenges for the creation and transfer of data are explained. Furthermore, new methods are being developed in order to improve both the technical and economic boundary conditions for the application of 3DP. This makes the production of models with very detailed interior rooms possible. The internal details are made visible by dividing the complex overall model into individual models connected by means of an innovative plug-in system. Finally, two case studies are shown in which the developed methods are applied in order to implement detailed architectural models. Additional information about manufacturing time and costs of the architectural models in the two case studies is given.
Architecture models are an essential component of the development process and enable a physical representation of virtual designs. In addition to the conventional methods of model production using the machining of models made of wood, metal, plastic or glass, a number of additive manufacturing processes are now available. These new processes enable the additive manufacturing of architectural models directly from CAAD or BIM data. However, the boundary conditions applicable to the ability to manufacture models with additive manufacturing processes must also be considered. Such conditions include the minimum wall thickness, which depends on the applied additive manufacturing process and the materials used. Moreover, the need for the removal of support structures after the additive manufacturing process must also be considered. In general, a change in the scale of these models is only possible at very high effort. In order to allow these restrictions to be adequately incorporated into the CAAD model, this contribution develops a parametrized CAAD model that allows such boundary conditions to be modified and adapted while complying with the scale. Usability of this new method is illustrated and explained in detail in a case study. In addition, this article addresses the additive manufacturing processes including subsequent post-processing.
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.
In addition to traditional methods in product development, the increasing availability of two new technologies, namely additive manufacturing AM (e.g. 3D-printing) and reverse engineering RE by means of 3D-scanning, offer new opportunities in product development processes today. However, to date only very few approaches exist those include these new technologies systematically in the education of students in the field of product development. This paper explores several ways in which AM and RE can productively be used in education. New to this approach is, on the one hand, that the students assemble and install the 3Dprinters themselves, and on the other hand, that they are introduced to an approach that combines 3D-scanning followed by 3D-printing. In different case studies is demonstrated that students in design education are able to autonomously research and realize technical possibilities and limitations of these technologies, as well as economic parameters and constraints.
Additive Manufacturing and Reverse Engineering have increasingly been gaining in importance over the past years. This paper investigates the current status of the implementation of these new technologies in design education and also identifies current shortcomings. Then it develops two new approaches for the teaching of the necessary expertise for the design of 3D-printed components and illustrates these with case studies. First, a workshop is presented in which students gain a broad understanding for the functionalities of additive manufacturing and the creative possibilities and limits of this process, through the assembly and installation of a 3D-printer. A second new approach is the combination of reverse engineering and 3D-printing. Thereby, students learn how to deal with this complex process chain. The result of these new approaches can e.g. be seen in the design guidelines for Additive Manufacturing, which were developed by the students themselves. At the same time, the students are able to estimate opportunities and limits of both technologies. Finally, the success of the new course contents and form is reviewed by an evaluation by the students.
In addition to traditional methods in product development, the increasing availability of two new 3D digital technologies, namely digital manufacturing (3D-printing) and digitizing of surfaces (3D-scanning), offer new opportunities in product development processes today. With regard to the systematic implementation of these technologies in the education of students in the field of product development, however, only a small number of approaches exist so far. This paper explores several ways in which 3D digital technologies can productively be used in design education. The innovative aspects here include that the students assemble and install the 3D-printers themselves, and that they are introduced to an approach that combines 3D-scanning followed by 3D-printing.
The use of architectural models is a long-proven method for the visualization of designs. More recently, powerful 3D printers have enabled the rapid and cost-effective additive manufacturing (AM) of textured architectural models. The use of AM technology to sample terraced houses in a specific use case (sampling center with more than 1200 customers per year) is examined within this contribution. The aim is to offer customers with limited spatial imagination assistance in the form of detailed architectural models of the whole house, which are divided into different modules. For this purpose, the structure of the terraced house is first analysed and examined for flexible design elements. The implementation of different variants of each floor should serve as a basis for the customer's decision on design and equipment. Thus, the architectural models are additively manufactured using Polyjet modeling. The necessary CAAD-data and interfaces, the technical possibilities and limits of this approach as well as the resulting costs are analyzed. The results of the AM process are evaluated to determine their applicability for the sampling of terraced houses. In addition, the evaluation will show that the additively manufactured architectural models will allow a more precise visualization of the building and thus a faster understanding of the design choices.
Direct Digital Manufacturing of Architectural Models using Binder Jetting and Polyjet Modeling
(2019)
Today, architectural models are an important tool for illustrating drawn-on plansor computer-generated virtual models and making them understandable. Inaddition to the conventional methods for the manufacturing of physical models, awide range of processes for Direct Digital Manufacturing (DDM) has spreadrapidly in recent years. In order to facilitate the application of these new methodsfor architects, this contribution examines which technical and economic resultsare possible using 3D printed architectural models. Within a case study, it will beshown on the basis of a multi-storey detached house, which kind of datapreparation is necessary. The DDM of architectural models will be demonstratedusing two widespread techniques and the resulting costs will be compared.
In the development of new vehicles, increasing customer comfort requirements and rising safety regulations often result in an increase in weight. Nevertheless, in order to be able to meet the demand for reduced fuel consumption, it is necessary within product development process to implement complex and filigree lightweight structures. This contribution therefore addresses the potential of generatively developed components for fiber-reinforced additive manufacturing (FRAM). Currently, several commercial systems for this application are available on the market. Therefore, a comparison of the systems is first made to determine a suitable system. Then, a highly stressed and safety-relevant chassis component of a race car is generatively designed and manufactured using FRAM. A matrix with short fiber reinforcement and additional long fiber reinforcement with carbon fibers is applied. Finally, tensile tests are carried out to check the mechanical properties. In addition, relevant properties such as weight and cost are obtained in order to be able to compare them with conventionally developed and manufactured components.
Additive manufacturing (AM), or 3D printing (3DP), has increasingly become more wide-spread and applied to a great degree over the past years. Along with that, the necessity for training courses which impart the required knowledge for product development with 3D printing rises. This article will introduce a “Rapid Prototyping” workshop which should convey to students the technical and creative knowledge for product development in using additive manufacturing. In this workshop, various 3D printers are initially installed and put into operation for the construction of self-assembly kits during the introduced training course. Afterwards, the students use databanks to select and download suitable components for the 3D print on the basis of criteria. Lastly, the students develop several assembly kits independently and establish design guidelines based on their experience. The students likewise learn to estimate and evaluate economic boundaries such as, e.g. costs and delivery times. For a start, it is a new approach to be using various assembly kits. These are up to date with current technology and dispose of features such as, e.g., additional nozzles for support material and heated building platforms. Moreover, a comprehensive evaluation of the training success will be conducted. The students’ level of knowledge in various areas will also be determined and compared with surveys taken before and after the conducting of the workshops. Additionally, cost and delivery time estimates and knowledge of databanks will be determined through concrete questioning.