Please enable JavaScript.
Coggle requires JavaScript to display documents.
Rationale - Coggle Diagram
Rationale
Change in Design Philosophy
Additive Manufacturing in the Building Industry
Concrete Technologies
3D printing of concrete moulds
[The Economist - 3D printing and clever computers could revolutionize construction] Dr. Block
Production of vaults centimetres thick
New thinner floors would only need a third of the material and frees up enough vertical space to have three floors where two would typically fit.
NEST Zurich
Blocks for vaults are produced only through CNC milling - AM opens the door for efficient manufacturing.
[The Economist - 3D printing and clever computers could revolutionize construction] FreeFAB
Molds printed from WAX which may be melted down and recycled
Formwork for panels
Double-cuvrature panels may be produced in 3 hours instead of 8 days of highly-skilled technical work.
MX3D bridge
Arup Node
Benefit of Additive Manufacturing for Production
[Bai, Liu, Wang - A pattern of technological accumulation. The comparative advantage and relative impact of 3D printing Technology].
Literature Review
3D printing technology formed by Charles Hull using a lasre to cure liquid polymers
In the budding stage (1980´s), three main technologies were used as selective laser sintering : stereography, laminated object manufactring and fused deposition
Rapid tooling was developed due to the use of heat-resistant polymers and metal alloys
AM can use numeorous materials, namely plastic, ceramics, metals, wood, salt.
Data and Mehtods
3D printing can be divided in 6 major technologies:
Curing tech.
Sintering and bonding tech.
Material melt bonding tech.
PLate laminated tech.
3D Bioprinting
3D food printing
The Netherlands exhibits intense superiority in sub-fields of 3D printing Technology and a high level of specialization in fast growing areas like Lase Sintering Technology. The Netherlands also exhibits a high level of specialization (although not necessarily an overall technical advantage at an international level) in the technical areas of Spray Bonding Technology, Wire Melt Bonding Technology and Powder / Granular Materials Melt Bonding Technology.
[Boothroyd - Product design for manufacture and assembly]
"Design is the first step in manufacturing, and it is where most of the important decisions are made that affect the final cost of a product".
The objective of a DFMA should be to utilize the capabilities of an individual manufacturing process to the fullest extent to keep the product as simple as possible.
Working with teams at the predesign stage deserves good credit an should be undertaken in every company. However, unless one can provide a basis for discussion that is grounded in quantified cost data and systematic design evaluations, directions wil often be dictated by the most forceful individual in the group, rather than guided by knowledge of the downstream results.
[Cranfield University - Cost estimation framework for WAAM parts]
Note
: BTF = Buy to Fly ratio (weight of raw material vs. weight of final component)
Increasing the deposition rate above 1 kg / hr has no economic benefit
Higher capital cost translates into higher hourly rates; increasing deposition rate reduces specific cost
Material removal rate does not really matter
Given the current condiditons, WAAM is always cheaper than machining
Increasing deposition rate is useless if also BTF increases
Podwer-Bed processes must build their cases on freedom of design, unitil cheaper and faster machines become available.
AM Empirical evidence for supply chain integration
[Delic, Eyers, Mikulic - Additive Manufacturing: Empirical evidence for supply chain integration and performance from the automotive industry]
AM offers potential to industry, but is also likely to have a significan impact on supply chain theory and practice.
AM adoption positively infuences supply chain performance and as a consequence, firm performance.
Supporting results-based view, results show a positive indirect effect on supply chain integration and firm performance
Introduction
AM may accelerate product development times, lessen product development cost, offer cabailities in both flexibility and agility, increase innovation performance, lessen need for spare parts inventory holding and yield products that could not otherwise be produced with conventional technologies.
On of the most popular applications is the auto industry, as it promises innovation in product dev. and significant financial saving by simplifying long and complex supply chains.
"competitive advantage" created should leverage the power of collaboration by connecting suppliers and costumers in complimentary business.
Theoretical background
AM adoption and supply chain performance
For suppliers: supply chain performance concerns the supplier's quality, flexibility. AM promotes rapid innovation and product modification, with quick changes in design. Through AM, delivery times can be reduced, and additional cost of part complexity and variability are significantly lower. than in traditional manufacturing.
For costumers: supply chain performance concerns product quality and feasibility. AM highlights accelerated product development with reduced time-to-market, increased product differentiation and faster order fulfillment.
AM is typically more economical at lower production volumes by eliminating constraints such as tooling, but also reducing material use, lower warehousing and transportation costs, and decreased inventory holding cost. Also Improves reliability on order fulfillment by moving responsive on-demand production to improve fill-rates, whilst reducing safety stocks and stock-out events.
AM improves time-to-market, rapidly prototyping designs and eliminating tooling, as well as improving responsiveness.
AM and supply chain integration
The extent to which a company can collaborate with partners and manage processes to achieve effective and efficient flows of products and services. This requires firms to improve their internal production capabilities and integrate supply chain partners - leading to open collaborative innovation philosophies.
Internal integration - how the function and procedures of the focal firm are integrated and synchronized. AM supports vertical integration.
AM supports closer integration between manufacturer and costumer, by supporting co-creation between manufacturer and costumer, greater responsiveness and highly specialized products.
-New tech. implementation represents a way to promote new functionalities and performance improvements for existing products. AM enables innovative production regardless of design complexity.
AM adoption represents a tool for efficient exchange of knowledge and production experience between OEM, key suppliers and costumers.
Supply chain integration and supply chain performance
Integration offers companies resources that are valuable and hard to imitate, enabling OEM to become more market responsive. Increasing overall supply chain performance is a key motivation for supply chain integration. Companies with highest levels of supplier and costumer integration had highest levels of performance in service quality, delivery, productivity, market share and profitability.
integrating Tier-1 suppliers within early-phase design activities has a positive impact on success and project performance in terms of quality and time-to-market.
Supply chain performance and firm performance
Whether the company is achieving its market-oriented and financial gals. Examining the impact of supply chain performance on firm performance determines the ability to positively affect the company's competitiveness. Effectiveness and efficiency are casually correlated. Effectiveness is a direct consequence of efficient supply chain management.
When a company develops characteristic supply chain capabilities through supply chain integration, it is likely to improve operational competencies and achieve competitive advantage in the market; supplier-oriented performance also affects firm performance improvement. .
Discussion
AM has strongest influence on costumer-oriented performance and reliability performance, but the weakest influence on cost-containment performance. AM technologies are cost-competitive for low production volumes and far less so in high volumes.
AM has the strongest influence on supplier integration and internal integration, but the weakest on costumer integration. For auto industry, costumers are satisfied with the selection of modules from different options rather than designing their own.
AM can make a positive impact in supply chain, but is not achieved in isolation. Many of traditional activities of supply chain management are still needed. AM are not a source of competitive advantage: they need to be incorporated within the supply chain.
A trend exists for automotive firms to increase focus on closer relationships with strategic suppliers to exploit specialist capabilities. Where AM supports supply chain integration, we expect a corresponding improvement in supply chain performance.
Where costumer integration is weak, this will need to improve for those companies attempting a costumer co-design and co-creation.
Companies need to think carefully about which products AM are best suited for, rather than blindly applying them across the entire product range. - Prioritize products were costumers most value the service benefits and where cost-sensitivity is lessened.
[Daredjat, Minshall - Implementation of rapid manufacturing for mass customization]
Mellor et. al. propose a framework for AM implementation by considering strategic, supply chain, operational, organisational and AM related technological factors and how these are influenced by external forces.There include:
AM Strategy (Alignment between business, manufacturing, and R&D)
The AM supply chain (AM system vendor, material suppliers, costumers, location of manufacture)
Systems of operations (Design for AM, AM process planning, quality control, AM cost accounting system, integration)
Organisational change (Business size, organizational structure, workforce experience and skill, organisational culture)
AM technology (AM standards, technology maturity, technology benefits and trade-offs, RP legacy)
External forces ( Competitive pressures, environmental legislation, costumer requirements)
[Eyers et. al]. The flexibility of industrial additive manufacturing systems
IAMS - industrial additive manufacturing systems
7 external capabilities of additive manufacturing
:
Flexibility to manufacture 'on demand' - (flexibility to manufacture in response to costumer's orders without penalties associated with conventional manufacturing)
Flexibility in design practice - (flexibility due to elimination of many constraints found in conventional manufacturing)
Flexibility to produce a wide range of parts
Flexibility to produce a wide range of complex geometries - (flexibility to achieve complex shapes relative to conventional approaches)
Flexibility to use many dfferent materials (flexibility in the material use and the processing technique)
Flexibility to fabricate products without tooling - (flexibility to manufacture without the need of part-specific tools)
Flexibility to exploit process variables for efficient production - (flexibility in the process variables that can be handled, and leads to accuracy and efficiency in part fabrication).
8 INternal flexibility competences
Flexibility witihn a manufacturing system arises through the attainment of internal flexibility competences
Equipment flexibility (The ability of the equipment to change between different operations) (Design ++ Pre-Process ++)
Process Fexibility (The ability to produce parts in the same manufacturing system in different ways) (manufacturing ++, Post-processing++)
Operation flexibility - (the ability to change the sequence in which production occurs) (Manufacturing ++)
Capacity flexibility - The ability to increase or decrease production capacity
Routing flexibility - The ability to change the route taken by parts through the production process
Program flexibility - the ability for equipment to operate unattended for extended time periods (Design -- , Pre-Process --, Manufacturing ++)
Material handling flexibility - The ability for materials to move effectively through the plant (Design ++, Pre-process++).
Emergent capabilities
Capability to re-sequence work
: Operations and routing flexibility by re-prioritizing fulfillment orders
Capability to vary volume of production
: able to address highly volatile and unpredictable demand. Plant resources are shown to be inflexible, labor resources support flexibility by moving between different jobs and exploiting multi-skill - rarely reported by IAMS.
Capability to improve system resilience
: AM machines are known to have reliability issues. May be achieved through routing flexibility, contingent on having spare capacity to accommodate work.
Capability for unattended production
: potential for AM machines to run unattended is well-documented. Lack of feedback tends to mean human observers, although not considered critical for operation.
Capability for achievement of smooth material flow
: digital nature of design information, with automation of material processing by AM machine offers a potential to achieve a material handling flexibility
Additive Manufacturing - A Brief Introduction
Design for Additive Manufacturing
[Wiberg, Persson, Ölvander - Design for Additive manufacturing - A review of available design methods and Software]
System Design
Component Design
Chose Component for AM - Identify the right product or component for AM. Identify type of component suitable. Identify added value AM brings. Identify potential interest of client to customize and design.
Define design problem - Identify adequate AM method. Identify AM boundaries and opportunities per manufacturing method available. Identify possible integration of multiple components to reduce assembly costs and increase functionality.
Define material, load cases, etc - Engineering work for identification of mechanical and environmental requirements.
Part Design
Creation of initial design - Formulation of initial design, possibly exploiting topological and manufacturing-specific optimization options.
Interpretation of initial design - Reconfiguration of initial design for explicit AM purposes, based on design guidelines for AM components.
Verification of Design - verification of design-interpretation through advanced modeling tools, including material heterogeneity and surface quality effects.
Process Design
Creation and evaluation of support structure - Automatically or performed manually in CAD, taking into consideration the build direction and geometry.
Additive Manufacturing preparation - Determination of the manufacturing parameters for production, including energy input, scan (travel) consumable format and controlled manufacturing conditions.
Validation of build time and cost - Using dedicated software and parametric cost estimation, validate the resources required for manufacturing procedure.
Additive Manufacturing simulation - Simulation of surface roughness in material output, dimensional stability, material's mechanical properties as process dependent, heat transfer mechanics and melt pool dynamics for manufacturing. AM simulation can occur at an stage of the part or process design, depending on the necessary insight.
Manufacturing and post-processing
Metal Additive Manufacturing
Structural Metals in Additive Manufacturing
Material requirements for Structural Components
Challenges and Opportunities
Topology Optimization
[Liu et. al. Current and future trends in topology optimization for additive manufacturing]
Support Structure Design
Support slimming
Overhang-free topology optimization
Porous infill design
Porous infill optimization
Lattice material optimization
Material feature in AM
Material anisotropy
Microstructure control via topology optimization
Multi-material and non-linear topology optimization
Multi-material topology optimization
Non-linear topology optimization (material non-linearities, viscosity and softening)
embeded functional components
active structures (piezoelectric components)
Robust design incorporating material uncertainities
topology optimization under material uncertainity
topology optimization under manufacturing uncertainity
Post-treatment
Post-machining
State of the art in Additive Manufacturing