Integrated product-process design: Material and manufacturing process selection for additive manufacturing using multi-criteria decision making

Abstract Market dynamics of today are constantly evolving in the presence of emerging technologies such as Additive Manufacturing (AM). Drivers such as mass customization strategies, high part-complexity needs, shorter product development cycles, a large pool of materials to choose from, abundant manufacturing processes, diverse streams of applications (e.g. aerospace, motor vehicles, and health care) and high cost incurred due to manufacturability of the part have made it essential to choose the right compromise of materials, manufacturing processes and associated machines in early stages of design considering the Design for Additive Manufacturing guidelines. There exists a complex relationship between AM products and their process data. However, the literature to-date shows very less studies targeting this integration. As several criteria, material attributes and process functionality requirements are involved for decision making in the industries, this paper introduces a generic decision methodology, based on multi-criteria decision-making tools, that will not only provide a set of compromised AM materials, processes and machines but will also act as a guideline for designers to achieve a strong foothold in the AM industry by providing practical solutions containing design oriented and feasible material-machine combinations from a current database of 38 renowned AM vendors in the world. An industrial case study, related to aerospace, has also been tested in detail via the proposed methodology.

[1]  Andy Anak Buja,et al.  Decision making with analytical hierarchy process (AHP) for viable manufacturing of SCRE , 2013 .

[2]  Neil Hopkinson,et al.  Rapid manufacturing : an industrial revolution for the digital age , 2006 .

[3]  Ali Siadat,et al.  Integrated product-process design to suggest appropriate manufacturing technology: a review , 2017 .

[4]  David W. Rosen,et al.  Computer-Aided Design for Additive Manufacturing of Cellular Structures , 2007 .

[5]  Jean-Pierre Kruth,et al.  ADDITIVE MANUFACTURING OF THERMOPLASTIC COMPOSITES , 2013 .

[6]  Christian Terwiesch,et al.  Product Development and Concurrent Engineering , 2000 .

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

[8]  Galina S. Maltugueva,et al.  Application of case-based reasoning and multi-criteria decision-making methods for material selection in petrochemistry , 2018 .

[9]  Ali Emrouznejad,et al.  The state of the art development of AHP (1979–2017): a literature review with a social network analysis , 2017, Int. J. Prod. Res..

[10]  Mary Kathryn Thompson,et al.  Process chain modeling and selection in an additive manufacturing context , 2016 .

[11]  Informatic.  Multi-Attribute Decision Making Using Simple Additive Weighting and Weighted Product in Food Choice , 2015 .

[12]  Paulo A. Cauchick Miguel,et al.  Additive manufacturing process selection based on parts’ selection criteria , 2015, The International Journal of Advanced Manufacturing Technology.

[13]  Ronald E. Giachetti,et al.  A decision support system for material and manufacturing process selection , 1998, J. Intell. Manuf..

[14]  S. Kumar,et al.  An Intelligent System for Modeling and Material Selection for Progressive Die Components , 2007 .

[15]  Frédéric Vignat,et al.  Metallic additive manufacturing: state-of-the-art review and prospects , 2012 .

[16]  Jean-Yves Dantan,et al.  Conceptual process planning - an improvement approach using QFD, FMEA, and ABC methods , 2010 .

[17]  Vincent Sitzmann,et al.  A Qualitative Assessment of Applications, Recent Trends and the Technology's Future Potential , 2015 .

[18]  Vittorio Alfieri,et al.  Reduction of Surface Roughness by Means of Laser Processing over Additive Manufacturing Metal Parts , 2016, Materials.

[19]  R. Mirshams,et al.  Study of Knowledge-Based System ( KBS ) and Decision Making Methodologies in Materials Selection for Lightweight Aircraft Metallic Structures , 2017 .

[20]  Joel Sauza Bedolla,et al.  A Proposal of Manufacturing Execution System Integration in Design for Additive Manufacturing , 2015, PLM.

[21]  Donny Indrawan.  Decision Making With Analytical Hierarchy Process (AHP) , 2012 .

[22]  Christoph Klahn,et al.  Design for Additive Manufacturing – Supporting the Substitution of Components in Series Products , 2014 .

[23]  Florentin Caloian,et al.  Additive Manufacturing Flickering at the Beginning of Existence , 2012 .

[24]  Michael Schmidt,et al.  Additive manufacturing in production: challenges and opportunities , 2015, Photonics West - Lasers and Applications in Science and Engineering.

[25]  Sharon L.N. Ford,et al.  Additive Manufacturing Technology: Potential Implications for U.S. Manufacturing Competitiveness , 2014 .

[26]  R. Ponche,et al.  A new global approach to design for additive manufacturing , 2012 .

[27]  Yong Huang,et al.  Additive Manufacturing: Current State, Future Potential, Gaps and Needs, and Recommendations , 2015 .

[28]  Michael R. Lovell,et al.  Material and process selection in product design using decision-making technique (AHP) , 2012 .

[29]  Morteza Yazdani,et al.  Analysis in Material Selection: Influence of Normalization Tools on COPRAS-G , 2017 .

[30]  Serge Tichkiewitch,et al.  Methodology and Product Model for Integrated Design Using a Multiview System , 1997 .

[31]  Antonio Armillotta,et al.  Selection of layered manufacturing techniques by an adaptive AHP decision model , 2008 .

[32]  Mirko Ficko,et al.  Multi-criteria selection of manufacturing processes in the conceptual process planning , 2017 .

[33]  Xuan F. Zha,et al.  A web-based advisory system for process and material selection in concurrent product design for a manufacturing environment , 2005 .

[34]  Jean-Yves Hascoët,et al.  A novel methodology of design for Additive Manufacturing applied to Additive Laser Manufacturing process , 2014 .

[35]  Saeed Mansour,et al.  Design opportunities with rapid manufacturing , 2003 .

[36]  R. C. Abeyaratne,et al.  A new application of ELECTRE III and revised Simos' procedure for group material selection under weighting uncertainty , 2008, Knowl. Based Syst..

[37]  Samuel H. Huang,et al.  Design for manufacture and design for `X`: concepts, applications, and perspectives , 2001 .

[38]  Brian Mellor,et al.  Multiple material additive manufacturing – Part 1: a review , 2013 .

[39]  Neil Hopkinson,et al.  Emerging Rapid Manufacturing Processes , 2006 .

[40]  Stuart A. Rosenfeld.  Manufacturing by Design , 2018, Economic Development Quarterly.

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

[42]  M. Coker,et al.  Microbiological quality of packaged bottled water and public water supply in Ibadan, Nigeria , 2006 .

[43]  Ian Gibson,et al.  Additive manufacturing technologies : 3D printing, rapid prototyping, and direct digital manufacturing , 2015 .

[44]  M. D. Monzón,et al.  Standardization in additive manufacturing: activities carried out by international organizations and projects , 2015 .

[45]  Pascal Lafon,et al.  Integrated Design in Additive Manufacturing Based on Design for Manufacturing , 2016 .

[46]  M. Maleque,et al.  MATERIALS SELECTION OF A BICYCLE FRAME USING COST PER UNIT PROPERTY AND DIGITAL LOGIC METHODS , 2010 .

[47]  Terry Wohlers,et al.  Wohlers report 2016 , 2016 .

[48]  Shankar Chakraborty,et al.  A combined TOPSIS-AHP-method-based approach for non-traditional machining processes selection , 2008 .

[49]  Christoph Klahn,et al.  Design Strategies for the Process of Additive Manufacturing , 2015 .

[50]  David Cebon,et al.  Materials Selection in Mechanical Design , 1992 .

[51]  David W. Rosen,et al.  Build Time and Cost Models for Additive Manufacturing Process Selection , 2012 .

[52]  Guillaume Mandil,et al.  Using additive and subtractive manufacturing technologies in a new remanufacturing strategy to produce new parts from End-of-Life parts , 2015 .