Design for additive manufacturing for small-volume production: A case study

Abstract

Additive manufacturing (AM), also referred to as 3D printing, is an innovative manufacturing method that constructs objects by adding layers based on digital models. Contrary to conventional subtractive manufacturing, which involves removing material to form shapes, AM involves adding material in precise layers. This method provides enhanced design flexibility and enables the production of intricate geometries while minimizing waste. This technology is employed in diverse industries such as aerospace, medical, automotive, and fashion, to produce prototypes, functional components, and customized designs. The ability to customize products makes efficiently and sustainably is a fundamental aspect of contemporary manufacturing and design innovation. The goal of this research is to find out how AM techniques can be used by people or companies with limited funding to replace conventional production methods, which typically involve expensive machinery, molding, and production line setup. Fused deposition modeling (FDM) and stereolithography (SLA), two 3D printing technologies that stand out from other AM technologies in terms of cost effectiveness and adaptability for home-use applications, are the primary subjects of this study. Case study and expert interviews are the research methods used in this study. An FDMmanufactured outdoor air quality control kit for the ITU campus is the focus of the case study. This kit was created as part of a scientific research project on smart and sustainable campuses. From the pre-production phase through the final form, the design process is assessed qualitatively and quantitatively. The design of the product, the choice of materials and printing technology, and surface quality are the main concerns of the assessment. The case study is supported by expert interviews, which provide a more thorough grasp of AM. Four specialists who work with FDM and SLA technologies development and apply it to different industries and contexts were selected. The experts are a mechanical engineer leading R&D at a company that makes classical mixers, and faucets, an industrial designer employed by a company that manufactures 3D printers; and a designer/owner of a startup company that uses FDM technology in R&D and final-product manufacturing processes. The results clarified the distinctions between the application of FDM and SLA techniques, the potential for material and time savings during product development, and the strategies for minimizing or eliminate support structures completely. The study also shows situations where AM techniques are more advantageous than conventional techniques at specific production volumes. The case study's numerical data demonstrated how alterations in printing and design techniques lower costs and speed up production. This study's conclusion highlights the potential and necessity of AM technology for small-scale, resource-constrained enterprises and low-volume production. The advantages AM providing over conventional production techniques hold great promise for the broad adoption of these technologies and the transformation of the paradigms that drive industrial production.