Chicken Nuggets and Additive Manufacturing Dr. Nick Meisel 10/20/15 1

In order to develop a successful product, it’s not enough just to think of its design 2 We must also be aware of how it will be manufactured!

A variety of traditional manufacturing processes have been around for decades or centuries 3 Casting Injection Molding Milling

Many traditional manufacturing methods can be classified as “subtractive manufacturing” 4

Over the past 20 years or so, we’ve seen the rise of new “additive manufacturing” methods 5

Additive manufacturing (AM, aka 3D printing) builds objects in a layer-wise fashion 6

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.” 7 Official Academic and Manufacturing Industry Term  3D Printing:  The commonly accepted public term for AM  Technically, a subset of AM (a specific process type) Today, we will use these interchangeably

There are 7 main types of AM processes 8 Vat Photopolymerization Material Jetting Binder Jetting Powder Bed Fusion Sheet Lamination Directed Energy Deposition Material Extrusion Ceramicindustry.com Lboro.ac.uk Blog.leapto3d.com Unirapid.com Kudo3d.com Ornl.gov Eos.info

Modern AM is used to create a wide variety of both prototypes and end use parts 9 Aerospace Medical Consumer Products

Researchers and manufacturers are coming up with new ways to use AM every day 10

Let’s talk in a bit more detail about one type of AM process that you are most likely familiar with 11

Material extrusion AM is one of the most popular and inexpensive forms of AM 12

With the patents having recently expired, we’ve seen an explosion of low-cost desktop AM systems 13 Makerbot Afinia Cube RepRap

Even with low-end desktop printing, we can still design using AM’s “free complexity” 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 15

The input to any 3D printer is called an.STL file 16 An STL file can be created from any CAD model in any program

.STL files are then sent to our printer’s proprietary software, where it translates it to path information 17

Now that you’re more familiar with how the process works, let’s talk about design 18

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? 19

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…. 20 Manufacturing Assembly Cost Environment Modularity Reliability Additive Manufacturing? Maintenance

Traditional Design and Mfg. are often separated 21 Designer Manufacturer Design for Manufacturing!

Design for manufacturing considerations help bridge the gap between designer and manufacturer 22 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. machining/

For Design for Additive Manufacturing (DfAM) we have two distinct things to consider 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) 24 “Free” ComplexityMass Customization Printed Assemblies Multiple MaterialsDecreased Iteration TimeReduced Material Waste

The layer-by-layer nature of AM allows for parts of almost infinite complexity 25 “If you can draw it, we can print it.”

The patternless nature of AM allows for every design to be unique, without added tooling cost 26 Protos Eyewear Sols Orthotics Invisalign Braces CT Scan of WindpipePrinted Model with Fitted Splints Mass Customization

By adding in appropriate tolerances, we can print assemblies that work right off the tray 27

With access to the entire volume as a part is printing, we can even embed foreign objects 28

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

Though AM can make incredibly complex structures, it still is subject to some DfM limits 30 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

Though AM can make incredibly complex structures, it still is subject to some DfM limits 31 Desktop extrusion printers require support material that must be manually removed

Though AM can make incredibly complex structures, it still is subject to some DfM limits 32 Build volumes can allow large parts, but we must be aware of curling

Though AM can make incredibly complex structures, it still is subject to some DfM limits 33 Orientation has a dominant effect on build time and quality ~ 1 hour ~5 hours Stair-stepping in cross-section Smooth cross-section

Question for Thought When should considerations for manufacturing (additive or subtractive) enter into the design process? 34 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” deep McDonald’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? 37 / Biomimicry Topology Optimization / Printed AssembliesSupport Removal Minimum Feature Size m/ Cellular Structures

Why bother with Design for X? Considering the manufacturing process can yield innovative ideas! (especially with AM) 38 Likely don’t need all of this material… Can’t we optimize this beam for better performance?

Key Takeaways 1.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 39

A final word… “Distracted driving causes 80% of all car accidents” 2009 National Highway Traffic Safety Administration /local/ _1_drink-and- drive-drivers-study Please, don’t drive distracted.

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