On Design for Additive Manufacturing: Review of Challenges and Opportunities utilising Visualisation Technologies

Design for additive manufacturing poses new challenges and opportunities for manufacturers to produce highly customised parts while reducing cost, production time and improving quality. Manufacturing constraints of conventional manufacturing methods, such as geometric complexity limitations and workpiece handling, have shaped the landscape of computer-aided design tools, which are therefore not suitably adapted to design for additive manufacturing. Furthermore, computer-aided design tools require a high level of training to produce appropriate models. Augmented reality and feedback technologies pose an interesting opportunity for design for additive manufacturing, whereby the interaction with 3D models in an augmented or virtual design space can provide intuitive feedback to engineers and designers, providing fast validation of designs, parametric modelling and opportunities for training and use in both professional and amateur designer communities. This paper will explore and review the opportunities this exciting new technology provides.

[1]  Karel Kellens,et al.  Environmental Dimensions of Additive Manufacturing: Mapping Application Domains and Their Environmental Implications , 2017 .

[2]  Sami Kara,et al.  Design, management and control of demanufacturing and remanufacturing systems , 2017 .

[3]  Takeo Igarashi,et al.  Situated modeling: a shape-stamping interface with tangible primitives , 2012, Tangible and Embedded Interaction.

[4]  Jyoti Mazumder,et al.  Design for Metallic Additive Manufacturing Machine with Capability for “Certify as You Build”☆ , 2015 .

[5]  Johann Habakuk Israel,et al.  Towards hybrid modelling environments—Merging desktop-CAD and virtual reality-technologies , 2010 .

[6]  Harry Bikas,et al.  Additive manufacturing methods and modelling approaches: a critical review , 2015, The International Journal of Advanced Manufacturing Technology.

[7]  Paul Witherell,et al.  Design Rules for Additive Manufacturing: A Categorization , 2017 .

[8]  M. Javaid,et al.  Role of CT and MRI in the design and development of orthopaedic model using additive manufacturing. , 2018, Journal of clinical orthopaedics and trauma.

[9]  Tek-Jin Nam,et al.  M.Sketch: Prototyping Tool for Linkage-Based Mechanism Design , 2016, UIST.

[10]  Richard J.M. Hague,et al.  Cost estimation for rapid manufacturing - laser sintering production for low to medium volumes , 2006 .

[11]  Michael Rohs,et al.  Let me grab this: a comparison of EMS and vibration for haptic feedback in free-hand interaction , 2014, AH.

[12]  Jonathan C. Roberts,et al.  Review of Designs for Haptic Data Visualization , 2010, IEEE Transactions on Haptics.

[13]  Tim Caffrey,et al.  Wohlers report 2013 : additive manufacturing and 3D printing state of the industry : annual worldwide progress report , 2013 .

[14]  Andrew Y. C. Nee,et al.  Augmented reality applications in design and manufacturing , 2012 .

[15]  Stefanie Mueller,et al.  3D printing for human-computer interaction , 2017, Interactions.

[16]  Przemysław Oborski,et al.  Man-machine interactions in advanced manufacturing systems , 2004 .

[17]  S. Pannala,et al.  The metallurgy and processing science of metal additive manufacturing , 2016 .

[18]  Takeo Igarashi,et al.  Plushie: an interactive design system for plush toys , 2007, SIGGRAPH 2007.

[19]  Ran Zhang,et al.  Functionality-aware retargeting of mechanisms to 3D shapes , 2017, ACM Trans. Graph..

[20]  David W. Rosen,et al.  Design for Additive Manufacturing , 2015, Additive Manufacturing Technologies.

[21]  Matthias Busse,et al.  INKtelligent printing® for sensorial applications , 2010 .

[22]  Mohsen Attaran,et al.  The rise of 3-D printing: The advantages of additive manufacturing over traditional manufacturing , 2017 .

[23]  John O. Milewski,et al.  Additive Manufacturing of Metals: From Fundamental Technology to Rocket Nozzles, Medical Implants, and Custom Jewelry , 2017 .

[24]  Nathaniel Hudson,et al.  Understanding Newcomers to 3D Printing: Motivations, Workflows, and Barriers of Casual Makers , 2016, CHI.

[25]  Claudio Pacchierotti,et al.  A three DoFs wearable tactile display for exploration and manipulation of virtual objects , 2012, 2012 IEEE Haptics Symposium (HAPTICS).

[26]  Hod Lipson,et al.  Freeform fabrication of zinc‐air batteries and electromechanical assemblies , 2004 .

[27]  Joseph J. Beaman,et al.  History of Additive Manufacturing and the 2009 Roadmap for Additive Manufacturing : Looking Back and Looking Ahead , .

[28]  Richard Leach,et al.  Review of in-situ process monitoring and in-situ metrology for metal additive manufacturing , 2016 .

[29]  Wai Yee Yeong,et al.  Laser and electron‐beam powder‐bed additive manufacturing of metallic implants: A review on processes, materials and designs , 2016, Journal of orthopaedic research : official publication of the Orthopaedic Research Society.

[30]  Hans-Werner Gellersen,et al.  ReForm: Integrating Physical and Digital Design through Bidirectional Fabrication , 2015, UIST.

[31]  Sean Follmer,et al.  Makers' Marks: Physical Markup for Designing and Fabricating Functional Objects , 2015, UIST.

[32]  Bernhard Mueller,et al.  Additive Manufacturing Technologies – Rapid Prototyping to Direct Digital Manufacturing , 2012 .

[33]  Patrick Baudisch,et al.  RoMA: Interactive Fabrication with Augmented Reality and a Robotic 3D Printer , 2018, CHI.

[34]  Georgia Albuquerque,et al.  Tangible 3D: hand gesture interaction for immersive 3D modeling , 2005, EGVE'05.

[35]  Yan Wang,et al.  Data-driven cost estimation for additive manufacturing in cybermanufacturing , 2018 .

[36]  Soh-Khim Ong,et al.  Virtual and Augmented Reality Applications in Manufacturing , 2004, MIM.

[37]  Domenico Prattichizzo,et al.  Shape and weight rendering for haptic Augmented Reality , 2010, 19th International Symposium in Robot and Human Interactive Communication.

[38]  Gabriel Taubin,et al.  3D Modeling by Scanning Physical Modifications , 2015, 2015 28th SIBGRAPI Conference on Graphics, Patterns and Images.

[39]  Yunbo Zhang,et al.  RealFusion: An Interactive Workflow for Repurposing Real-World Objects towards Early-stage Creative Ideation , 2016, Graphics Interface.

[40]  Tovi Grossman,et al.  RetroFab: A Design Tool for Retrofitting Physical Interfaces using Actuators, Sensors and 3D Printing , 2016, CHI.

[41]  F. Martina,et al.  Design for Additive Manufacturing , 2019 .

[42]  B. Colosimo,et al.  Process defects and in situ monitoring methods in metal powder bed fusion: a review , 2017 .

[43]  Bernd Fröhlich,et al.  The cubic mouse: a new device for three-dimensional input , 2000, CHI.

[44]  Eyal Ofek,et al.  NormalTouch and TextureTouch: High-fidelity 3D Haptic Shape Rendering on Handheld Virtual Reality Controllers , 2016, UIST.

[45]  J. Hoerber,et al.  Approaches for Additive Manufacturing of 3D Electronic Applications , 2014 .

[46]  I. Ashcroft,et al.  Topology Optimization for Additive Manufacturing , 2011 .

[47]  Martin Hachet,et al.  One Reality: Augmenting How the Physical World is Experienced by combining Multiple Mixed Reality Modalities , 2017, UIST.

[48]  Sandra Hirche,et al.  Control sharing in human-robot team interaction , 2017, Annu. Rev. Control..

[49]  Pedro Lopes,et al.  Providing Haptics to Walls & Heavy Objects in Virtual Reality by Means of Electrical Muscle Stimulation , 2017, CHI.

[50]  Peter Schröder,et al.  Surface drawing: creating organic 3D shapes with the hand and tangible tools , 2001, CHI.

[51]  Pier Paolo Valentini,et al.  Interactive virtual assembling in augmented reality , 2009 .

[52]  Gideon Levy,et al.  RAPID MANUFACTURING AND RAPID TOOLING WITH LAYER MANUFACTURING (LM) TECHNOLOGIES, STATE OF THE ART AND FUTURE PERSPECTIVES , 2003 .

[53]  Shawn P. Moylan,et al.  Measurement Science Needs for Real-time Control of Additive Manufacturing Powder Bed Fusion Processes , 2015 .

[54]  Jean-Yves Hascoët,et al.  A new DFM approach to combine machining and additive manufacturing , 2011, ArXiv.

[55]  Eleonora Atzeni,et al.  Economics of additive manufacturing for end-usable metal parts , 2012 .

[56]  Stephen Reay,et al.  Tools for Sustainable Product Design: Additive Manufacturing , 2010 .

[57]  Eren Özceylan,et al.  Impacts of Additive Manufacturing on Supply Chain Flow: A Simulation Approach in Healthcare Industry , 2017 .

[58]  Jun Ni,et al.  A review of 4D printing , 2017 .

[59]  Geert-Jan van Houtum,et al.  Traditional or Additive Manufacturing? Assessing Component Design Options through Lifecycle Cost Analysis , 2018, Eur. J. Oper. Res..

[60]  Carolyn Conner Seepersad,et al.  Challenges and Opportunities in Design for Additive Manufacturing , 2014 .

[61]  Pedro Lopes,et al.  Adding Force Feedback to Mixed Reality Experiences and Games using Electrical Muscle Stimulation , 2018, CHI.

[62]  Vincent Hargaden,et al.  A novel paradigm for managing the product development process utilising blockchain technology principles , 2019, CIRP Annals.

[63]  Madeline Gannon,et al.  Tactum: A Skin-Centric Approach to Digital Design and Fabrication , 2015, CHI.

[64]  Richard A. Volz,et al.  Evaluation of a Haptic Mixed Reality System for Interactions with a Virtual Control Panel , 2005, Presence: Teleoperators & Virtual Environments.

[65]  Vincent Hargaden,et al.  Product lifecycle management and digital manufacturing technologies in the era of cloud computing , 2017, 2017 International Conference on Engineering, Technology and Innovation (ICE/ITMC).

[66]  Yosep Oh,et al.  Part decomposition and assembly-based (Re) design for additive manufacturing: A review , 2018, Additive Manufacturing.

[67]  Hod Lipson,et al.  ModelCraft: capturing freehand annotations and edits on physical 3D models , 2006, UIST.

[68]  Richard J.M. Hague,et al.  Additive Manufacturing for Mass Customization , 2011 .

[69]  Richard J.M. Hague,et al.  The cost of additive manufacturing: machine productivity, economies of scale and technology-push , 2016 .

[70]  A. Clausen Topology Optimization for Additive Manufacturing , 2016 .

[71]  Andrew J. Pinkerton,et al.  Lasers in additive manufacturing , 2016 .

[72]  Ignacio Llamas,et al.  Twister: a space-warp operator for the two-handed editing of 3D shapes , 2003, ACM Trans. Graph..

[73]  Guha Manogharan,et al.  Making sense of 3-D printing: Creating a map of additive manufacturing products and services , 2014 .