Skip to main content
Disciplines
Automotive Business IT + Informatics Construction + Real Estate Electrical Engineering + Electronics Energy + Sustainability Insurance + Risk Finance + Banking Management + Leadership Marketing + Sales Mechanical Engineering + Materials
Events
DE
EN
Books
Journals
Topic Page
Marketing
Start single access now
Access for companies
EXTENDED SEARCH
Log in
Top
Published in:
Cover of the book

2018 | Supplement | Chapter

Evolution of Design Guidelines for Additive Manufacturing - Highlighting Achievements and Open Issues by Revisiting an Early SLM Aircraft Bracket

Authors : Christoph Klahn, Daniel Omidvarkarjan, Mirko Meboldt

Published in: Industrializing Additive Manufacturing - Proceedings of Additive Manufacturing in Products and Applications - AMPA2017

Publisher: Springer International Publishing

Log in

Activate our intelligent search to find suitable subject content or patents.

search-config
loading …

Abstract

Design knowledge is important for the success of new technologies. This is especially true for Additive Manufacturing technologies like Selective Laser Melting (SLM), which offer a higher degree of freedom, but also very different restriction in design compared to conventional manufacturing technologies. An analysis of current and previous designs from aerospace and motorsports identifies important drivers in Design for Additive Manufacturing. To visualize the advances in design knowledge an SLM aircraft bracket is re-designed based on today’s state of the art almost 10 years after its initial design for additive manufacturing. The analysis reveals important factors for a “good” design. In early designs the focus of engineers was on the manufacturability of the part itself, while the capabilities of CAD tools limited the designer. Nowadays designs show a more holistic view on the manufacturing process chain and the part’s application, e.g. by integrating provisions for conventional post-processing and fatigue optimized shapes and surfaces. Some issues are still open and need to be addressed in the next generation of guidelines, tools and equipment.

Dont have a licence yet? Then find out more about our products and how to get one now:

Springer Professional "Wirtschaft+Technik"

Online-Abonnement

Mit Springer Professional "Wirtschaft+Technik" erhalten Sie Zugriff auf:

  • über 102.000 Bücher
  • über 537 Zeitschriften

aus folgenden Fachgebieten:

  • Automobil + Motoren
  • Bauwesen + Immobilien
  • Business IT + Informatik
  • Elektrotechnik + Elektronik
  • Energie + Nachhaltigkeit
  • Finance + Banking
  • Management + Führung
  • Marketing + Vertrieb
  • Maschinenbau + Werkstoffe
  • Versicherung + Risiko

Jetzt Wissensvorsprung sichern!

inform now

Springer Professional "Technik"

Online-Abonnement

Mit Springer Professional "Technik" erhalten Sie Zugriff auf:

  • über 67.000 Bücher
  • über 390 Zeitschriften

aus folgenden Fachgebieten:

  • Automobil + Motoren
  • Bauwesen + Immobilien
  • Business IT + Informatik
  • Elektrotechnik + Elektronik
  • Energie + Nachhaltigkeit
  • Maschinenbau + Werkstoffe




 

Jetzt Wissensvorsprung sichern!

inform now
next chapter A Design Method for SLM-Parts Using Internal Structures in an Extended Design Space
Literature
1.
Meiners, W.: Direktes Selektives Laser Sintern einkomponentiger metallischer Werkstoffe. Berichte aus der Lasertechnik. Shaker, Aachen (1999)
2.
Cloots, M., Uggowitzer, P.J., Wegener, K.: Investigations on the microstructure and crack formation of IN738LC samples processed by selective laser melting using Gaussian and doughnut profiles. Mater. Des. 89, 770–784 (2016)CrossRef
3.
Spierings, A.B., Dawson, K., Voegtlin, M., Palm, F., Uggowitzer, P.J.: Microstructure and mechanical properties of as-processed scandium-modified aluminium using selective laser melting. CIRP Ann. - Manufact. Technol. 65(1), 213–216 (2016)CrossRef
4.
5.
6.
Lee, J.J., Lukachko, S.P., Waitz, I.A., Schafer, A.: Historical and future trends in aircraft performance, cost and emissions. Annu. Rev. Energy Env. 26, 167–200 (2001)CrossRef
7.
Greene, D.L.: Commercial air transport energy use and emissions: is technology enough? In: Conference on Sustainable Transportation-Energy Strategies (1995)
8.
Johnson, V.S.: Minimizing life cycle cost for subsonic commercial aircraft. J. Aircr. 27(2), 139–145 (1990)CrossRef
9.
Klahn, C.: Topologische Optimierung der Gestaltung von lasergenerierten Funktionsbauteilen der Luftfahrttechnik. Diplomarbeit. Institute of Laser and System Technologies (iLAS), TU Hamburg-Harburg, Hamburg (2008)
10.
Onuh, S.O., Yusuf, Y.Y.: Rapid prototyping technology: applications and benefits for rapid product development. J. Intell. Manuf. 10, 301–311 (1999)CrossRef
11.
Trenke, D.: Konstruktionsregeln für eine Rapid Tooling gerechte Gestaltung von Werkzeugen und Prototypen. IMW - Institutsmitteilung 25, 85–90 (2000)
12.
Rehme, O., Emmelmann, C.: Reproducability for properties of selective laser melting products. In: Beyer, E., Dausinger, F., Ostendorf A., Otto, A. (eds.) Proceedings of the Third International WLT-Conference on Lasers in Manufacturing 2005. AT-Fachverlag, München (2005)
13.
Aumund-Kopp, C., Petzoldt, F.: Laser sintering of parts with complex internal structures. In: Lawcock, R., Lawley, A., McGeehan, P.J. (eds.) Advances in Powder Metallurgy & Particulate Materials - 2008, pp. 85–97. Metal Powder Industries Federation, Princeton (2008)
14.
Burton, M.J.: Design for rapid manufacture: developing an appropriate knowledge transfer tool for industrial designers. Ph.D. thesis, Loughborough University, Loughborough (2005)
15.
Hopkinson, N., Hague, R.J., Dickens, P.M. (eds.): Rapid Manufacturing: An Industrial Revolution for the Digital Age. Wiley, Chichester (2006)
16.
Thomas, D.: The development of design rules for selective laser melting. Ph.D. thesis, University of Wales Institute, Cardiff (2009)
17.
Adam, G.A.O., Zimmer, D.: Design for additive manufacturing - element transitions and aggregated structures. CIRP J. Manufact. Sci. Technol. 7, 20–28 (2014)CrossRef
18.
Adam, G.A.O.: Systematische Erarbeitung von Konstruktionsregeln für die additiven Fertigungsverfahren Lasersintern, Laserschmelzen und Fused Deposition Modeling, Forschungsberichte des Direct Manufacturing Research Centers, vol. 1. Shaker, Aachen (2015)
19.
Kranz, J., Herzog, D., Emmelmann, C.: Design guidelines for laser additive manufacturing of lightweight structures in TiAl6V4. J. Laser Appl. 27, S14001 (2015)CrossRef
20.
Verein Deutscher Ingenieure - VDI: Additive Fertigungsverfahren - Konstruktionsempfehlungen für die Bauteilfertigung mit Laser-Sintern und Laser-Strahlschmelzen (2015)
21.
Wohlers, T.T., Caffrey, T.: Wohlers Report 2015: 3D Printing and Additive Manufacturing State of the Industry Annual Worldwide Progress Report. Wohlers Associates, Fort Collins (2015)
22.
Vogel, H., Tangwiriyasakul, C., Emmelmann, C.: Analysis of cooling channel design for injection molds manufactured by laser freeform fabrication. In: Vollertsen, F. (ed.) Proceedings of the Fourth International WLT-Conference on Lasers in Manufacturing 2007. AT-Fachverlag, München (2007)
23.
Meckley, J., Edwards, R.: A study on the design and effectiveness of conformal cooling channels in rapid tooling inserts. Technol. Interface J. 10(1), 1–28 (2009)
24.
Emmelmann, C., Petersen, M., Kranz, J., Wycisk, E.: Bionic lightweight design by laser additive manufacturing for aircraft industry. In: Ambs, P., Curticapean, D., Emmelmann, C., Knapp, W., Kuznicki, Z.T., Meyrueis, P.P. (eds.) SPIE Eco-Photonics 2011 Sustainable Design, Manufacturing, and Engineering Workforce Education for a Green Future, vol. 8065. Society of Photo-Optical Instrumentation Engineers (SPIE), Strassburg (2011)
25.
Emmelmann, C., Sander, P., Kranz, J., Wycisk, E.: Laser additive manufacturing and bionics: redefining lightweight design. Phys. Procedia 12, 364–368 (2011)CrossRef
26.
Kruth, J.P., Vandenbroucke, B., Vaerenbergh, J.V., Mercelis, P.: Benchmarking of different SLS/SLM processes as rapid manufacturing techniques. In: International Conference on Polymers and Moulds Innovations (PMI). University of Texas, Gent (2005)
27.
Bendsøe, M.P.: Optimal shape design as a material distribution problem: structural optimization, computer-aided optimal design of stressed systems and components. Struct. Optim. 1(4), 193–202 (1989)CrossRef
28.
Kantareddy, S.N.R., Ferguson, I., Frecker, M., Simpson, T.W., Dickman, C.J.: Topology optimization software for additive manufacturing: a review of current capabilities and a real-world example. In: ASME 2016 International Design Engineering Technical Conferences and Computers and Information in Engineering Conference, p. V02AT03A029. Charlotte, NC (2016)
29.
Klahn, C., Gysemberg, R., Rehme, O.: Stütze für ein im Selective Laser Melting-Verfahren herstellbares Flugzeugstrukturbauteil. German Patent DE 10 2008 044 759 B4 (2010)
30.
Leutenecker-Twelsiek, B., Klahn, C., Meboldt, M.: Considering part orientation in design for additive manufacturing. Procedia CIRP 50, 408–413 (2016)CrossRef
31.
Klahn, C., Leutenecker, B., Meboldt, M.: Design strategies for the process of additive manufacturing. Procedia CIRP 36, 230–235 (2015)CrossRef
32.
Carter, W.T., Erno, D.J., Abbott, D.H., Bruck, C.E., Wilson, G.H., Wolfe, J.B., Finkhousen, D.M., Tepper, A., Stevens, R.G.: The GE aircraft engine bracket challenge: an experiment in crowdsourcing for mechanical design concepts. In: 25th Solid Freeform Fabrication Symposium (SFF 2014), pp. 1402–1411. University of Texas, Austin, TX (2014)
33.
Leuders, S., Thöne, M., Riemer, A., Niendorf, T., Tröster, T., Richard, H.A., Maier, H.J.: On the mechanical behaviour of titanium alloy TiAl6V4 manufactured by selective laser melting: fatigue resistance and crack growth performance. Int. J. Fatigue 48, 300–307 (2013)CrossRef
34.
Edwards, P., Ramulu, M.: Fatigue performance evaluation of selective laser melted Ti-6Al-4V. Mater. Sci. Eng., A 598, 327–337 (2014)CrossRef
35.
Spierings, A.B., Starr, T.L., Wegener, K.: Fatigue performance of additive manufactured metallic parts. Rapid Prototyp. J. 19(2), 88–94 (2013)CrossRef
36.
Brandl, E., Heckenberger, U., Holzinger, V., Buchbinder, D.: Additive manufactured AlSi10Mg samples using selective laser melting (SLM): microstructure, high cycle fatigue, and fracture behavior. Mater. Des. 34, 159–169 (2012)CrossRef
Metadata
Title
Evolution of Design Guidelines for Additive Manufacturing - Highlighting Achievements and Open Issues by Revisiting an Early SLM Aircraft Bracket
Authors
Christoph Klahn
Daniel Omidvarkarjan
Mirko Meboldt
Copyright Year
2018
Book
Industrializing Additive Manufacturing - Proceedings of Additive Manufacturing in Products and Applications - AMPA2017

Print ISBN: 978-3-319-66865-9

Electronic ISBN: 978-3-319-66866-6

Copyright Year: 2018

DOI
https://doi.org/10.1007/978-3-319-66866-6_1

Premium Partners

    Image Credits