Chicken Nuggets andAdditive Manufacturing

Dr. Nick Meisel10/20/15

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In order to develop a successful product, it’s not enough just to think of its designWe must also be aware of how it will be manufactured!

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A variety of traditional manufacturing processes have been around for decades or centuries

CastingInjection Molding

Milling

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Many traditional manufacturing methods can be classified as “subtractive manufacturing”

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Over the past 20 years or so, we’ve seen the rise of new “additive manufacturing” methods

Additive manufacturing (AM, aka 3D printing) builds objects in a layer-wise fashion

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You’ve probably been hearing a lot about 3D printing, but not additive manufacturing

• Additive Manufacturing:• “…the process of joining materials to make objects from

3D model data, usually layer upon layer, as opposed to subtractive manufacturing methodologies. Synonyms are additive fabrication, additive processes, additive techniques, additive layer manufacturing, layer manufacturing, and freeform fabrication.”

Official Academic and Manufacturing Industry Term

3D Printing:The commonly accepted public term for AMTechnically, a subset of AM (a specific process

type)

Today, we will use these interchangeably

There are 7 main types of AM processes

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Vat Photopolymerization

Material Jetting

Binder Jetting

Powder Bed Fusion Sheet LaminationDirected Energy Deposition

Material Extrusion

Ceramicindustry.com

Lboro.ac.ukBlog.leapto3d.com

Unirapid.comKudo3d.com

Ornl.gov Eos.info

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Modern AM is used to create a wide variety of both prototypes and end use parts

Aerospace

Medical

Consumer Products

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Researchers and manufacturers are coming up with new ways to use AM every day

Let’s talk in a bit more detail about

one type of AM process that you are most likely familiar

with11

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Material extrusion AM is one of the most popular and inexpensive forms of AM

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With the patents having recently expired, we’ve seen an explosion of low-cost desktop AM systems

Makerbot

Afinia

Cube

RepRap

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Even with low-end desktop printing, we can still design using AM’s “free complexity”

http://www.cs.berkeley.edu/~sequin/SCULPTS/sequin.html

http://designreform.net/2008/04/fdm-3d-printing

http://www.3ders.org/articles/20120518-tiny-planetary-gears-set-3d-printed-on-a-makerbot-replicator.html

Let’s take a look at one of the new

Makerbot systems to give you a better idea

of how it works

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https://www.youtube.com/watch?v=DU9v71o5Udk

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The input to any 3D printer is called an .STL fileAn STL file can be created from any CAD model in any program

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.STL files are then sent to our printer’s proprietary software, where it translates it to path information

Now that you’re more familiar with how the process works, let’s talk

about design

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Recall the main phases of the design process

• Phase 0: Planning• What is the market opportunity?

• Phase 1: Concept Development• What are the customer needs?• Generate concepts

• Phase 2: System-Level Design• Generate product architecture• Identify subsystems

• Phase 3: Detail Design• Define and choose materials

• Phase 4: Testing and Refinement• Test reliability and performance

• Phase 5: Production Ramp-Up• How will this be made?

Design for X methods can improve product quality• System of design guidelines for a particular issue or product

characteristics that occur during a product’s lifecycle• Design for….

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ManufacturingAssembly Cost

EnvironmentModularity Reliability

Additive Manufacturing?

Maintenance

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Traditional Design and Mfg. are often separated

Designer Manufacturer

Design for Manufacturing!

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Design for manufacturing considerations help bridge the gap between designer and manufacturer

Design for Manufacturing (DfM) is the process of designing products to account for various

manufacturing functions with the goal of increasing product quality, reliability, safety, etc.

http://dfmpro.geometricglobal.com/processes/dfmpro-for-machining/

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For Design for Additive Manufacturing (DfAM) we have two distinct things to consider

1. Innovative design concepts that relate well to AM (e.g., mass customization, “free” complexity, printed assemblies, embedding, etc.)

2. Specific manufacturing limitations imposed by our chosen AM process type

AM offers a wide variety of design advantages (too many to cover in one class session)

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“Free” Complexity

Mass Customization

http://stratasys.com/

Printed Assemblies

http://makepartsfast.com/

Multiple Materials

Decreased Iteration TimeReduced Material Waste

http://matse.psu.edu/

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The layer-by-layer nature of AM allows for parts of almost infinite complexity

“If you can draw it, we can print it.”

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The patternless nature of AM allows for every design to be unique, without added tooling cost

Protos Eyewear

Sols Orthotics

Invisalign Braces

CT Scan of Windpipe Printed Model with Fitted Splints

Mass Customization

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By adding in appropriate tolerances, we can print assemblies that work right off the tray

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With access to the entire volume as a part is printing, we can even embed foreign objects

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For Design for Additive Manufacturing (DfAM) we have two distinct things to consider

1. Innovative design concepts that relate well to AM (e.g., mass customization, “free” complexity, printed assemblies, embedding, etc.)

2. Specific manufacturing limitations imposed by our chosen AM process type

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Though AM can make incredibly complex structures, it still is subject to some DfM limits

Every printer has a minimum feature size which determines how small an object it can create

Tied to the X-Y motor resolution, deposition method, material type

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Though AM can make incredibly complex structures, it still is subject to some DfM limits

Desktop extrusion printers require support material that must be manually removed

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Though AM can make incredibly complex structures, it still is subject to some DfM limits

Build volumes can allow large parts, but we must be aware of curling

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Though AM can make incredibly complex structures, it still is subject to some DfM limits

Orientation has a dominant effect on build time and quality

~ 1 hour~5 hours

Stair-stepping in cross-sectionSmoothcross-section

Question for Thought

• When should considerations for manufacturing (additive or subtractive) enter into the design process?

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Think about this as we perform today’s exercise.

The Challenge: DfAM• Design a means for storing an open chicken nugget sauce container in

your car so that you can “dip and drive” safely.

• Designs will be manufactured via desktop-scale, extrusion AM• Teams of 4• End result should be a CAD representation of your design (1:1 scale)

• Select a print orientation as well! (and provide a reason for it)35

Hold both Wendy’s and McDonald’s sauce!

Wendy’s: 2” in diameter, 0.5” deepMcDonald’s: 1.5” x 2” x 0.5”(both have small lip on top)

You have 50

minutes!36

Questions for Thought• Did you think about the manufacturing process during your design?• When should considerations related to AM enter the design process?• Conceptual?• System-Level?• Detailed?• All of the above?• Never?

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http://ecotrainingblog.blogspot.com/

Biomimicry

http://altairenlighten.com/

Topology Optimization

http://stratasys.com/

Printed AssembliesSupport Removal

http://isis3d.net/

Minimum Feature Size

http://cubex3dprinting.blogspot.com/

Cellular Structures

Why bother with Design for X?• Considering the manufacturing process can yield innovative ideas!

(especially with AM)

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Likely don’t need all of this material…

Can’t we optimize this beam for better performance?

Key Takeaways1. Design for X has the potential to improve product design

through concurrent engineering

2. Design for Manufacturing bridges the gap between designer and manufacturer• Fast iteration offered by AM can facilitate this interaction

3. Emphasis on DfAM will help to encourage innovative designs as this disruptive technology continues to grow

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A final word…“Distracted driving causes 80% of all car accidents”

2009 National Highway Traffic Safety Administration

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http://articles.nydailynews.com/2009-07-19/local/17928504_1_drink-and-drive-drivers-study

Please, don’t drive distracted.

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