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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.
Besides of conventional CAD systems, new, cloud-based 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. This contribution examines newly developed, cloud-based CAD systems. In the context of a case study, the application of these new CAD systems are investigated in the training of engineers in design education. Thus, the students compare a conventional and a cloud-based CAD system as part of an exercise of designing and 3D modelling of a pinion shaft. Subsequently, the students manufacture a drawing with different views of the pinion shaft. This assessment evaluates different criteria such as user-friendliness, tutorial support and installation effort.
Additive manufacturing processes have evolved rapidly in recent years and now offer a wide range of manufacturing technologies and workable materials. This range from plastics and metals to paper and even polymer plaster composites. Due to the layer by layer structure of the components the additive processes have in comparison with conventional manufacturing processes the advantage of freedom of design, that means the simple implementation of complex geometries. Moreover, the additive processes provide the advantage of reduced consumption of resources, since essentially only the material is consumed, which is required for the actual component, since no waste in the form of chips is produced. In order to use these advantages, the potentials of additive manufacturing and the requirements of sustainable design must already be observed in the product development process. So the design of the components and products must be made so as little as possible construction and supporting material is required for the generative production and therefore little resources are consumed. Also, all steps of the additive manufacturing process must be considered properly, that includes the post processing. This allows components be designed so that for instance the effort for removing the support structure is considerably reduced. This leads to a significant reduction in manufacturing time and thus energy consumption. The implementation of these potentials in product development can be demonstrated by means of a multiple-stages model. A case study shows how this model is applied in the training of Master students in the field of product development. In a workshop the students work as a group while implementing the task of developing a miniature racing car under the rules of sustainable design in compliance with the boundary conditions for an additive manufacturing. In this case, Fused Deposition Modelling FDM using plastics as a building material is applied. The results show how the students have dealt with the different requirements and how they have implemented them in product development and in the subsequent additive manufacturing.
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.
Virtuelle Modell "begreifbar" Machen - Darstellung von Simulationsergebnissen mittels 3D-Farbdruck
(2016)
Today, Additive Manufacturing (AM) is an important part of teaching for the education of future engineers. Therefore, a variety of approaches have been developed in recent years on how to bring the design for additive manufacturing (DfAM) into university teaching. In a detailed literature review, the advantages and disadvantages of the previous approaches are considered and analysed. Based on this, an extended approach is presented in which students analyse and optimize a given product with respect to additive manufacturing. In doing so, the students have to solve challenging tasks in optimization in product development with the help of methodical approaches and practically implement their developed solutions with state-of-the-art additive processes. To work on this task, the students have two different 3D printers at their disposal, which work with different processes and materials. Thus, the students learn to adapt the design to different manufacturing processes and to consider the restrictions of different materials. The assessment of the results from this course is done through feedback and a written survey.