Indiana University-Purdue University Indianapolis (IUPUI) / One of the primary challenges faced in Additive Manufacturing (AM) is reducing the overall cost and printing time. A critical factor in cost and time reduction is post-processing of 3D printed (3DP) parts, which includes removing support structures. Support is needed to prevent the collapse of the part or certain areas under its own weight during the 3D printing process. Currently, the design of self-supported 3DP parts follows experimental trials. A trial and error process is needed to produce high quality parts by Fused Depositing Modeling (FDM). An example for a chamfer angle, is the common use of 45 degree angle in the AM process. Surfaces that are more flat show defects than inclined surfaces, and therefore a numerical model is needed. The model can predict the problematic areas at a print, reducing the experimental prints and providing a higher number of usable parts. Physical-based models have not been established due to the generally unknown properties of the material during the AM process. With simulations it is possible to simulate the part at different temperatures with a variety of other parameters that have influence on the behavior of the model. In this research, analytic calculations and physical tests are carried out to determine the material properties of the thermoplastic polymer Acrylonitrile - Butadiene - Styrene (ABS) for FDM at the time of extrusion. This means that the ABS is going to be extruded at 200C to 245C and is a viscus material during part construction. Using the results from the physical and analytical models, i.e., Timoshenko’s modified beam theory for micro structures, a numerical material model is established to simulate the filament deformation once it is deposited onto the part. Experiments were also used to find the threshold for different geometric specifications, which could then be applied to the numerical model to improve the accuracy of the simulation. The result of the nonlinear finite element analysis is compared to experiments to show the correlation between the prediction of deflection in simulation and the actual deflection measured in physical experiments. A case study was conducted using an application that optimizes topology of complex geometries. After modeling and simulating the optimized part, areas of defect and errors were determined in the simulation, then verified and and measured with actual 3D prints.

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There is a gap in scientific knowledge regarding designing functional parts that may not fail, and this project came to define these parts as critical structures. The proposed design process is called the Additive Design Process for Critical Structure, which synthesizes required activities found in the literature review necessary to produce theoretically safe design structures. Although this proposed design process does not meet the requirements of a safe design as intended and must be further studied before the proposed design process can be adapted. The project’s ambition was to integrate the design’s safety with value components, referred to as elements/activities/tools/processes that could contribute to innovation and value creation, to exploit the advantages of additive manufacturing in the design process. The research conducted in this project adapted and applied Design Research Methodology (DRM), written by Blessing & Chakrabarti (2009). Two main research questions were studied that lay a foundation for this thesis, presented below. The project combined quantitative and qualitative research methods to generate the necessary knowledge and then apply/test the derived knowledge to answer these research questions. RQ1: What activities can this project identify to synthesize an additive design process in constructing critical structures for Additive Manufacturing (AM)? RQ2: What are the possible value components to include in the additive design process that would contribute to innovation concerning lead time, weight, and mass customization? The results show that the proposed design process, Additive Design Process for Critical Structured, did not meet the theoretical safe design. However, the findings still suggest that the required activities to achieve a safe design are by introducing defined and explicit protective measurements in the design process. The protective measurement parameters identified in this project were safety factors and Finite Element Analysis (FEA); the question of why the design process does not meet the requirements of producing a theoretical safe design is unknown today and needs further study. Concerning the second RQ, the results showed that Generative Design (GD) was this project's most innovative value component. Adapting GD contributed to shortening the product development time, liberating the design engineer to explore a bolder concept, reducing weight, and allowing the design engineers to generate mass customization. Keywords: Design for Additive Manufacturing, Design Process, Generative Design, Method, Critical Structures, Safety factor.

京都大学 / 新制・課程博士 / 博士(工学) / 甲第24849号 / 工博第5166号 / 新制||工||1987(附属図書館) / 京都大学大学院工学研究科機械理工学専攻 / (主査)教授 泉井, 一浩, 教授 松原, 厚, 教授 平山, 朋子 / 学位規則第4条第1項該当 / Doctor of Philosophy (Engineering) / Kyoto University / DFAM

Subtractive manufacturing are the most common methods in the aerospace industry to manufacture components. In these parts the buy to fly ratio is low and it needs accurate strengths analyses to static and dynamic loads especially were the different parts relate to each other with fasteners in the assembly work. Additive manufacturing has now been developed to be of such quality that the aerospace industry see the potential to use the technology in their production of parts. It has been possible to make them lighter, stronger and reduce the total amount of parts in an assembly. This mean probably some changes to the stakeholders in the process of their product development. Engineers who are working on the products will need to face the design aspects and restrictions with AM to choose the right component/sub-assemblies to convert to AM parts. This thesis will address the possibility to redesign a wing rudder and to get some knowledge about the engineer’s point of view of AM and how it may affect them. Today there are several aerospace industries adopting AM and get airworthy components to less critical parts as brackets but also parts in the engines as the fuel nozzle in an Airbus (Trimble, 2016). For larger parts, there have also been studies to use AM for example internal galley partition but the result is it will take too long time to print by todays machines. There are several different methods for AM and Powder Bed System is popular in the aerospace industry according to its geometrical correctness to the CAD model (Dordlofva, Lindwall, & Törlind, 2016). Commercial aircrafts industry starts to get harder regulations for their emissions to get lighter planes and less air resistance. AM open up the possibilities to meet these requirements by producing parts which was impossible to produce before. The design process for AM design today are not fully known yet, which leave a lot to imagination. There are general design rules on how to design for AM build but it does not necessary mean the part will be correctly built. There are several cost driven aspects with AM, the most expensive part is the print time but there are different aspects to. For example, CNC machining may be needed after the AM build and add cost for subtractive manufacturing. Interviews with engineer’s groups have been made to conduct their thoughts and knowledge of AM and how it may affect their work. Some uncertainties were mentioned and it was most focused on the process and the reliability of the finished part. The engineers think the design process will be almost the same and only change boundary conditions. To get ideas, a workshop was made with some design guidelines for development of different designs on the wing rudder and to bring positive and negative aspects to the design. An overall cost calculation was made for a few parts and the result shows that it is hard to compete with the design of the wing rudder today. The most important aspects for a success of AM is the print speed, qualified manufacturing processes and CAD software support for the engineers. / Flygindustrin använder sig främst av subtraktiv bearbetning i sin framställning av de olika komponenterna till ett flygplan. Det blir då ofta en väldigt låg grad av materialutnyttjande, endast några procent återstår av det inköpta utgångsmaterialet. Till det tillkommer monteringsarbete och noggranna hållfasthetsanalyser, både statisk och utmatningshållfasthet av sammanbyggda skarvar där fästelement är en del. Den additiva tillverkningen har nu utvecklats och visat sig inneha kvalitéer för att klara kraven som ställs i flygindustrin. Det kan göra detaljerna lättare, starkare och minska antalet komponenter i monteringsarbetet. Det kan innebära en hel del förändringar för olika intressenter som får börja tänka annorlunda. Ingenjörer som arbetar med produktframtagning kommer att ställas inför utmaningen att applicera denna teknik på lämpliga delar/delkonstruktioner. Detta examensarbetet undersöker möjligheten att designa ett vingroder till ett flygplan och bilda en uppfattning om ingenjörernas förtroende för additiv tillverkning samt hur det kommer påverka dem. Det finns idag flera flygindustrier som har påbörjat att ta fram flygvärdiga komponenter, framförallt mindre kritiska fästelement men även en del artiklar i motorer så som bränslemunstycke hos Airbus (Trimble, 2016). De har analyserat möjligheten att använda additiv tillverkning på större artiklar såsom inre kabinstruktur men har kommit fram till att det tar för lång tid att tillverka med dagens maskiner. Det finns flertalet olika additiva tillverkningsmetoder men den som står ut är pulverbäddskrivaren då den har en bättre geometrisk korrekthet gentemot CAD modellen (Dordlofva, Lindwall, & Törlind, 2016). Nya reglementen för utsläpp i den komersiella flygindustrin pressar företagen att bygga bättre flygplan som är lättare och därmed får mindre luftmotstånd. Designprocessen för additiv tillverkning är inte given då det inte finns några givna processer som täcker hela processen. Det finns generella design-riktlinjer i vad de olika maskinerna klarar av att bygga, men samtidigt är det ingen garanti att genom att följa dessa riktlinjer skapa en fungerande design. Det finns flera olika kostnadsdrivande aspekter med additiv tillverkning. Det som mest driver kostnaden idag är den låga skrivarhastigheten. Andra kosnadsdrivare är om det tillkommer efterarbete för att uppfylla toleranser eller få en korrekt / plan sammanfogningsyta. Arbetet har utförts med intervjuer av ingenjörsgrupper för att skapa en uppfatting om deras syn på additiv tillverkning och hur det skulle ändra deras arbete. En viss osäkerhet förekom men det berodde framförallt på osäkerheten för säkring av processen, dvs tillverkningsprocessen och att kunna vara säker på att detaljen håller måttet. De ansåg att designprocessen inte skulle förändras så mycket, utan bara att randvillkoren skulle ändras. Utifrån workshops och designriktlinjer har koncept tagits fram och utvärderats med för och nackdelar. En översiktlig kostnadskalkyl har gjorts som visar på att det blir svårt att designa roder som en större enhet för additiv tillvekning som är ekonomiskt jämförbart med dagens tillverkingsmetoder. De viktigaste framgångsfaktorerna för additiv tillverkning är ökad skrivarhastighet, kvalificering av tillverkningsprocesserna och CAD stöd för ingenjörerna.

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Additive manufacturing (AM), or 3D printing, is a collection of production processes that has received a good deal of attention in recent years from different industries. Features such as mass production of customised products, design freedom, part consolidation and cost efficient low volume production drive the development of, and the interest in, these technologies. One industry that could potentially benefit from AM with metal materials is the space industry, an industry that has become a more competitive environment with established actors being challenged by new commercial initiatives. To be competitive in these new market conditions, the need for innovation and cost awareness has increased. Efficiency in product development and manufacturing is required, and AM is promising from these perspectives. However, the maturity of the AM processes is still at a level that requires cautious implementation in direct applications. Variation in manufacturing outcome and sensitivity to part geometry impact material properties and part behaviour. Since the space industry is characterised by the use of products in harsh environments with no room for failure, strict requirements govern product development, manufacturing and use of space applications. Parts have to be shown to meet specific quality control requirements, which is done through a qualification process. The purpose of this thesis is to investigate challenges with development and qualification of AM parts for space applications, and their impact on the product development process. Specifically, the challenges with powder bed fusion (PBF) processes have been in focus in this thesis. Four studies have been carried out within this research project. The first was a literature review coupled with visits to AM actors in Sweden that set the direction for the research. The second study consisted of a series of interviews at one company in the space industry to understand the expectations for AM and its implications on product development. This was coupled with a third study consisting of a workshop series with three companies in the space industry. The fourth study was an in-depth look at one company to map the qualification of manufacturing processes in the space industry, and the challenges that are seen for AM. The results from these studies show that engineers in the space industry work under conditions that are not always under their control, and which impact how they are able to be innovative and to introduce new manufacturing technologies, such as AM. The importance of product quality also tends to lead engineers into relying on previous designs meaning incremental, rather than radical, development of products is therefore typical. Furthermore, the qualification of manufacturing processes relies on previous experience which means that introducing new processes, such as AM, is difficult due to the lack of knowledge of their behaviour. Two major challenges with the qualification of critical AM parts for space applications have been identified: (i) the requirement to show that critical parts are damage tolerant which is challenging due to the lack of understanding of AM inherent defects, and (ii) the difficulty of testing parts in representative environments. This implies that the whole product development process is impacted in the development and qualification of AM parts; early, as well as later stages. To be able to utilise the design freedom that comes with AM, the capabilities of the chosen AM process has to be considered. Therefore, Design for Manufacturing (DfM) has evolved into Design for Additive Manufacturing (DfAM). While DfAM is important for the part design, this thesis also discusses its importance in the qualification of AM parts. In addition, the role of systems engineering in the development and qualification of AM parts for space applications is highlighted.

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The work herein is, in part, motivated by the idea of creating optimized, actuating structures using additive manufacturing processes (AM). By developing a consistent, repeatable method for designing and manufacturing multi-material compliant mechanisms, significant performance improvements can be seen in application, such as increased mechanism deflection. There are three distinct categories of research that contribute to this overall motivating idea: 1) investigation of an appropriate multi-material topology optimization process for multi-material jetting, 2) understanding the role that manufacturing constraints play in the fabrication of complex, optimized structures, and 3) investigation of an appropriate process for embedding actuating elements within material jetted parts. PolyJet material jetting is the focus of this dissertation research as it is one of the only AM processes capable of utilizing multiple material phases (e.g., stiff and flexible) within a single build, making it uniquely qualified for manufacturing complex, multi-material compliant mechanisms. However, there are two limitations with the PolyJet process within this context: 1) there is currently a dearth of understanding regarding both single and multi-material manufacturing constraints in the PolyJet process and 2) there is no robust embedding methodology for the in-situ embedding of foreign actuating elements within the PolyJet process. These two gaps (and how they relate to the field of compliant mechanism design) will be discussed in detail in this dissertation. Specific manufacturing constraints investigated include 1) "design for embedding" considerations, 2) removal of support material from printed parts, 3) self-supporting angle of surfaces, 4) post-process survivability of fine features, 5) minimum manufacturable feature size, and 6) material properties of digital materials with relation to feature size. The key manufacturing process and geometric design factors that influence each of these constraints are experimentally determined, as well as the quantitative limitations that each constraint imposes on design. / Ph. D.