Abstract: The growing need for sustainable mobility is driving the search for solutions to reduce energy waste and harmful environmental emissions. In this context, the design of vehicle lighting presents a promising approach. The use of composite materials, along with the automation of their manufacturing and assembly processes, is increasingly in demand to strike a balance between cost, lightweight, and the required performance of vehicle chassis. Carbon Fiber Sheet Molding Compounds allow complex car body parts to be produced through a one-step compression molding process. Manual labor represents a crucial operation in preparing the compound charge and subsequent manipulation towards compression molding. However, it directly affects productivity. The continuity between the preparation and manipulation phases can be relaxed by implementing robotic solutions to handle the pre-shaped uncured composite charge, automating loading onto the press mold. Efficient robotic handling requires grippers designed to match the shape of the compound charge. Specifically, the gripper must control the deformation of the temporary form of the composite charges, ensuring that the shape deviations stay within acceptable limits for proper fit in the compression mold. This work presents a systematic approach to designing and optimizing robotic grippers to pick up and place deformable compound layers. The key design parameter that guides this method is the maximum distortion threshold, which regulates the process in the two stages. The first stage focuses on finding the optimal balance between the lowest grasping points and acceptable distortion to define the grasping layout. In contrast, the second stage addresses the gripper structure, aiming to create the lightest, yet stiffest frame. The approach is fully integrated into a computer-assisted design platform.

Keywords: CF-SMC | Integrated design | Limp uncured composite geometries | PLM Platform | Robotic Grippers

Abstract: Directed Energy Deposition (DED) is increasingly utilized for the construction of large components, repair of worn and damaged parts, and integration into Hybrid Manufacturing systems to leverage diverse technological features. A burgeoning application of DED is in Additive Remanufacturing (ARem), by which existing components can be enhanced with additional features and materials to improve functionalities. This paper presents a systematic and integrated approach for Design for Additive Remanufacturing (DARem), focusing on the optimization of product structural requirements to enhance performance and the process design to minimize flaws while ensuring material integrity and expected tolerances. The suggested approach involves product and process design phases within a computer aided design platform. Identification of critical issues in the original product design is the fundamental phase that drives the selection of the appropriate materials and quantities for deposition. Next, topological optimization is employed to shape and position additional volumes, generating enhanced design variants. A simulation phase ends the product design steps, assessing the actual improvement of the component over its original design. Subsequent phases are related to process design assessment. Selection of process parameters and build strategies, and next, the behavioral simulation of deposition are fundamental to verify feasibility and generate paths instructions. Finally, thermomechanical simulation is conducted to estimate the final component state accurately, ensuring it meets functional requirements before proceeding to actual manufacturing pre-processing, material deposition, and post-processing phases. A case study involving an automotive suspension component is used to demonstrate the feasibility of the proposed integrated approach. Experimental phases are performed to define DED material properties for the redesign and investigate the reliable simulation of process-induced distortions. By reducing stress in critical areas through localized deposition of 316L stainless steel alloy using laser powder DED, the study explores the impact of toolpath strategies on process-induced distortions through a Design of Experiments (DoE) approach. The results confirm the feasibility of the deposition process in meeting functional requirements, particularly geometrical tolerances, highlighting the potential of DARem for the redesign and enhancement of existing components.

Keywords: 316L, Remanufacturing | Directed Energy Deposition | Finite Element Method | Product-Process design

Abstract: The integration of automation into the Compression Molding process for mass production of automotive components using Carbon Fiber Sheet Molding Compound (CF-SMC) represents a significant improvement in the sector. It improves efficiency, precision, and safety while reducing production costs and allowing product customization. A review of current technologies highlights the limitations of manual lay-up and the potential of automated pick-and-place systems to transfer uncured charges from the preform stage to the mold. Needle grippers have emerged as the most suitable solution to minimize the retention time of composite material in the heated mold, reducing the risk of premature curing. This study proposes a validation model to analyze the needle insertion process, which includes the piercing, detachment, transfer, and release phases, with the goal of developing a numerical model capable of accurately replicating real physical behavior. Focusing on the piercing phase, the analytical model identifies key design parameters that correlate the insertion force, the tilt angle, and the geometry of the needle and the CF–SMC. Subsequently, a hybrid FEM–SPH numerical model, known for its suitability to simulate large-deformation problems, was then implemented in Abaqus.

Keywords: Carbon Fiber Sheet Molding Compound (CF-SMC) | Compression molding | Integrated design | Robotic Grippers

Abstract: The increasing pressure to decarbonize manufacturing systems is pushing industry beyond conventional lightweighting strategies toward material and process paradigms, capable of delivering functional performance with radically lower environmental impact. In this context, polymer-based composite Additive Manufacturing (AM) offers an underexplored yet highly promising pathway for sustainable production of load-bearing components. This study presents a preliminary comparative cradle-to-gate Life Cycle Assessment (LCA) of a Formula SAE brake pedal, assessing the environmental transition from conventional sheet metal fabrication and finishing operations of Aluminum 7075-T6 to additive manufacturing solutions, with specific focus on Carbon-Fiber-Reinforced Polymer (CFRP) composites. Two topology-optimized designs, respectively for Powder Bed Fusion (PBF) in AlSi10Mg and Material Extrusion (MEX) in Polyethylene Terephthalate Glycol with Carbon Fiber (PETG-CF) are compared to conventional fabrication aluminum benchmark. The analysis is integrated in the product and process design following ISO 14040/14044 standards and is implemented using the Environmental Footprint 3.0 methodology within the 3DEXPERIENCE platform. Results outline that Material Extrusion (MEX) composite manufacturing achieves the lowest environmental impact across all evaluated categories. Compared to conventional manufacturing, the PETG-CF solution enables an approximate 50% reduction in Global Warming Potential and an almost complete elimination of mineral depletion. Unlike metal additive manufacturing, which remains constrained by high process energy demand, MEX benefits from low processing temperatures, minimal auxiliary systems, and highly efficient material deposition. Crucially, these sustainability gains are achieved while maintaining functional performance through design-driven topology optimization. AM composite solutions, by merging advanced material science with additive flexibility, may lead to design approaches which cease to be \'potential\' enablers of sustainable manufacturing for the Industry 5.0 transition.

Keywords: Additive Manufacturing (AM) | Automotive Lightweight Design | Carbon Footprint Reduction | Design for Sustainability | Fused Deposition Modeling (FDM) | Life Cycle Assessment (LCA) | Sustainable Manufacturing | Topology Optimization

Abstract: Design optimization through the integration of multiple functions into a single part is a highly effective strategy to reduce costs, simplify assembly, improve performance, and reduce weight. Additive manufacturing facilitates the production of complex structures by allowing parts consolidation, resulting in optimized designs, where multiple functions are integrated into a single component. This study presents a design for additive manufacturing method for integrating multiple lattice structures to achieve thermal management and shock absorption functions. The method follows modeling and simulation phases for dimensioning and optimizing solutions to deliver the design functions at different macro- and mesoscale levels. Hierarchical complexity was leveraged to design the two-levels structure in a single part, each delivering a specific function. Specifically, the external layer addresses energy absorption and thermal insulation, while the internal layer acts as a thermal battery by incorporating a phase change material. The design of a container carried by an unmanned aerial vehicle for the transport of healthcare and biological materials is presented. The container is shock-resistant and can maintain the content at 4 ± 2 °C for at least 1 h. As it operates passively without the need for additional energy-consuming devices, it is easy to operate and contributes to increased flight autonomy. A flight mission experiment for urgent transport of blood bags confirmed the capability of the container to preserve blood integrity. This case study demonstrates that the two-layer lattice structure design represents a highly efficient approach to multifunctional design optimization.

Keywords: 3D printing | cellular structure | functional integration | fused deposition modeling | gyroid | impact absorption | multi-scale design | thermal insulation | triply periodic minimal surface | unmanned aerial system

Abstract: Nowadays, modern vehicles comprise a vast number of components made from various materials and manufactured using different techniques, making the management of assemblability, functionality, and cost highly complex. This complexity necessitates controlling geometrical and dimensional deviations to meet product and process demands. Dimensional Management (DM), supported by standards such as ASME-GD&T and ISO-GPS, is increasingly employed for geometrical specification and tolerance analysis. Through Computer-Aided Tolerancing (CAT) tools, tolerances can be considered early in the design process using Design for Tolerancing (DfT) approaches. This study aims to develop and define a methodology for geometric specification allocation and tolerance stack-up analysis of automotive components. The methodology integrates predictive models, DM, and DfT approaches via computer-aided tolerance specification and analysis, enabling comprehensive modeling and simulation of tolerance effects on performance, quality, and assemblability.

Keywords: Geometric Dimensioning and Tolerancing | Geometrical Product Specification | Model Based Definition | Tolerance design

Abstract: Conventional ground-based transport systems often experience delays due to congested traffic. This is unacceptable in the case of transporting organs, blood, medicines and emergency supplies, when time is critical. Urban Air Mobility (UAM) offers a solution to overcome transportation inefficiencies. In fact, Unmanned Aerial Systems (UAS) can quickly reach remote locations providing critical care in a timely manner. However, ensuring efficiency, safety and compliance with regulations is essential. This paper presents the mission-oriented design approach of a UAS, focusing on two subsystems, namely the Unmanned Aircraft (UA) and the Functional Container (FC). The design of the UA involves choices for configuring its layout. The FC design focuses on the preservation of the transported material. Lightweight and reliable dedicated solutions are designed for FC leveraging Additive Manufacturing (AM) technology. The design is mission-oriented, but allows systems to be reconfigured for additional missions.

Keywords: Advanced air mobility | Drone | medical | mission-oriented design | Unmanned air vehicle

Abstract: Directed Energy Deposition is mainly adopted for the construction of large parts and structures or the reparation of worn and damaged components, but also in Hybrid Manufacturing systems, to combine features of different technologies. An additional emerging application is the Remanufacturing of existing components by integrating further features and materials to enhance products’ functionality. Nevertheless, residual stress and strain are among the most relevant drawbacks since thermal gradients and cooling rates are more intensive compared to other Metal Additive Manufacturing processes. With the aim to define the build strategies (e.g.: tool paths and scanning patterns) for multiple depositions on actual existing components and mitigate the substrate deformation, this work is focused on the laser-based Direct Metal Deposition process design and optimization. To find the best trade-off between process efficiency and product quality, the goal is achieved identifying the build strategies (i) to guarantee the expected product requirements and (ii) to provide functional and assembly requirements. The case study is the Additive Remanufacturing of an automotive component, requiring a functional tolerance control, which implies to contain process-induced distortion. The build process is assessed through Finite Element thermo-mechanical simulations of 316L deposition, cooling, and unclamping steps. The effects of factors as the deposition strategy, orientation, direction, and sequence, are studied through a Design of Experiments approach. The model maximum displacement is the primary response, and the build time is the secondary one.

Keywords: AISI 316L | Finite element method | Laser metal deposition | Process optimization | Process simulation

Abstract: In recent years, Additive Manufacturing has experienced significant growth, yet its full potential is constrained by the lack of clear and easily replicable Design for Additive Manufacturing (DfAM) methodologies. Focusing on the product design stage, the current design approach for topology optimized parts involves an iterative re-design process to identify and reduce stress concentrations based on NURBS modelling, which is hardly replicable and heavily influenced by the designer’s experience. This work aims to define two new workflows for DfAM that are easily replicable, highly automated, and based on numerical optimization tools. Leveraging the optimization tools available in 3DExperience integrated CAD platform, after topology optimization, the first workflow involves generating the skeletonization of the resulting geometry and reconstructing it with parametric surfaces, reducing maximum stresses via parametric optimization. The second workflow reconstructs the resulting optimized geometry as a non-parametric B-Rep surface, optimizing maximum stresses through automatic shape optimization.

Keywords: 3DExperience | Additive Manufacturing | Design for Additive Manufacturing | Design method | Design optimization | Parametric optimization | Shape optimization | Topology optimization

Abstract: With the advent of additive manufacturing (AM) and advanced fiber-reinforced composites, integrating orthotropic material behavior into the design phase is increasingly essential. Unlike isotropic assumptions typically used in topology optimization (TO), orthotropic materials exhibit direction-dependent properties that significantly impact mechanical performance, especially in the build direction due to AM layer-wise construction. Traditional workflows often separate design and manufacturing stages, leading to suboptimal structures when material anisotropy is ignored. This study proposes a design framework that embeds orthotropic elasticity into TO using the Solid Orthotropic Material with Penalization (SOMP) method. Material orientation, directly linked to part build direction, is treated as a variable influencing both product performance and process sustainability. A flat lamina case study illustrates how different fiber alignments affect mechanical behavior, while a second case involving a Formula SAE brake pedal demonstrates the feasibility of redesigning metal parts for composite AM. Key performance indicators (KPIs) are evaluated across material orientations to assess trade-offs in structural performance and manufacturing efficiency. Co-optimizing material orientation and geometry would allow to enhance stiffness-to-weight ratios and reduce waste and post-processing. The findings demonstrate the feasibility of further integrated product and process optimization using topology optimization of orthotropic materials.

Keywords: 3D Printing | CFRP | Design for Additive Manufacturing | Finite Element Method | Material Anisotropy | Sustainable manufacturing

Abstract: The growing demand for automation in industrial production, especially in the automotive industry, has made it crucial to adopt integrated design methodologies that ensure efficiency, quality, and shorter product development timelines. Currently, the design of welded assemblies involves several stages: product design, design of the related welding fixtures, definition of the welding process, and subsequent evaluation of residual stresses. This process requires effective management of product and process data through a well-organized flow across design iterations. In this context, assuming a robotic welding automation process, this study introduces an approach for designing, simulating, and optimizing welded assemblies using a single, integrated software platform that combines CAD, CAM, and CAE functionalities. The platform supports the development of a streamlined workflow covering the entire design process for welded joints: from component modeling to thermo-structural simulation of the robotic welding process, and assessment with specific key performance indicators. The approach was applied to a case study involving a simplified automotive chassis, aiming to identify the most effective welding sequence in terms of minimizing product deformations and reducing process execution time. The results confirm the viability of the proposed method and highlight new opportunities for using integrated digital tools in the design of complex products and processes.

Keywords: Integrated approach | Process effectiveness indicator | Product and process design | Robotic welding

Abstract: This paper presents a computer-based methodology to support the design for additive manufacturing of metal components. Metal additive manufacturing, and in particular powder bed fusion systems, are playing a prominent role in the industry 4.0 scenario. The state of the art concerning design methods and tools to support design for additive manufacturing is reviewed by the authors. The key phases of product design and process design to achieve lightweight functional designs and reliable processes are deepened, and the computer-aided technologies to support the approaches implementation are described. Indeed, the state of the art design for additive manufacturing general workflow can be enriched by holistic approaches, use of numerical simulation, and integration and automation between the required tasks. The paper provides a methodology based on the systematic use of numerical simulation to achieve the optimization of both products and associated processes. To take advantage of the holistic perspective, the approach relies on the use of integrated product-process design platforms, allowing to streamline the digital process chain. Product design is based on the systematic integration of topology optimization and automatized tools for concept development and selection and subsequent product simulation driven design refinement. Process design is based on a systematic use of process simulation to prevent manufacturing flaws related to the high thermal gradients of metal processes and minimize residual stress and deformations. This is achieved by working on both the build cycles layouts and the 3D models’ distortion compensation. An automotive use case of product and process design performed through the proposed simulation-driven integrated approach is provided to assess the actual method suitability for effective re-designs of additive manufacturing high-performance metal products. The bridged gaps are systematically outlined, and further developments are discussed.

Keywords: Computer-aided engineering | Design method | Design optimization | Finite element method | Integrated design | Process simulation

Abstract: The supply of automotive spare parts, especially for historic vehicles, is not guaranteed by car manufacturers. Usually, car restorers look for original components at flea markets and fairs, but often they have to produce replicas from broken parts or, worse, without information about the original parts. A possible support in mechanical craftsmanship comes from digital tools commonly used in industry today. With the goal of replicating a component that no longer exists, this paper provides a workflow that integrates traditional manufacturing technologies with computer-based tools. The core is the digital model, which is used to prototype and test the replica for functionality as well as simulate its manufacturing process. An engine valve cover of a historic racing car was chosen as a case study, for which information sources were practically unobtainable. Firstly, a 3D model and a 3D printed prototype were developed. Sand casting was chosen based on the original process and computer simulations allowed to reconstruct the casting equipment and define the best part design. A faithful and functional replica is then manufactured and assembled with the original engine, respecting the original part in terms of form, materials and production. The proposed design approach can be further adopted in different contexts requiring on-demand, one-off or small-batch production.

Keywords: 3D modelling | Additive Manufacturing | Car restoration | Component reproduction | Computer-Aided Engineering | Sand casting

Abstract: Additive Manufacturing (AM) Powder Bed Fusion (PBF) metal processes enable significant design freedom, addressing design complexity in high-end sectors. To build performant products, several Design for Additive Manufacturing guidelines must be considered. Nevertheless, it is still noticeable a lack of reliability for AM processes, which is a key factor to guarantee both the expected enhanced product requirements and the manufacturability. Even though few rules and best practices to mitigate defects are provided either by standards or equipment suppliers, they are still missing approaches to predict build failures and process flaws, and therefore achieve faultless build processes. This work suggests a concurrent product and process design approach, in which Computer Aided Engineering tools are involved in both product and process design to identify the components’ shapes that match the expected performance and a feasible PBF build layout. An automotive component is the use case, whose design based on topology optimization and product validation is enriched by integrating the associated process simulation. The build process is modeled by (a) the additive manufacturing simulation to identify flaws and resources usage, and (b) the thermo-mechanical finite element -based simulation to predict residual stress and distortions. The approach based on CAD platforms integrates product and process design to reduce design iterations, trial-error practices, and build failures.

Keywords: Design for Additive Manufacturing | Finite Element Analysis | Laser Powder Bed Fusion | Process simulation | Product-process design

Abstract: Composite materials, pioneered by aerospace engineering due to their lightness, strength, and durability properties, are increasingly adopted in the high-performance automotive sector. Besides the acknowledged composite components' performance, enabled lightweighting is becoming even more crucial for energy efficiency, and therefore emissions along vehicle use phase from a decarbonization perspective. However, their use entails energy-intensive and polluting processes involved in the production of raw materials, manufacturing processes, and particularly their end-of-life disposal. Carbon footprint is the established indicator to assess the environmental impact of climate-changing factors on products or services. Research on different carbon footprint sources reduction is increasing, and even the European Composites Industry Association is demanding the development of specific Design for Sustainability approaches. This paper analyzes the early strategies for providing low-carbon aerospace and automotive composite components by design. The goal is to enable design approaches that consider the material life cycle from product and process design, material selection and fabrication, to eventual recycling and reuse. The investigation includes the design approaches and tools, and the aspects concerning ultimate trends of materials development, shapes generation, and manufacturing processes. Among these, we discuss the potential role of emerging technologies such as digital intelligence, Biocomposites, biomimicry, generative AI, and additive manufacturing. The aim is to identify the framework of possible drivers for Design for Sustainability approaches, rethinking lightweight products lifecycles and highlighting the resulting challenges and future developments. Moreover, as practical examples, a few innovative cases are provided to prove the effective potentials of such guidelines. The conclusive remarks discuss the advantages and disadvantages of the design drivers and the need for assessment and validation through vehicle Life Cycle Assessment approaches.

Abstract: Robotic Additive Manufacturing is an emerging trend thanks to effective advances compared to traditional machines based on Cartesian movements. Reduction of the volume of supports and the related “staircase effect” increased inaccuracy and surface roughness, large printing volumes, more flexibility on the printing strategy, and use of multiple materials are just some of the potential benefits returned by robotic additive manufacturing. Nevertheless, the selection of suitable strategies, planning of the printing trajectories and definition of the related code to drive the robot movements are still managed by different digital tools that make it challenging to identify the optimal process. This work describes a Design for Robotic Additive Manufacturing approach to support the development of the printing process driven by complex machines such as robotic arms. Based on an available computer-aided design platform, the digital replica of the robotic system is recreated, and additive process alternatives are applied to simulate the fabrication of an automotive part. A first assessment of the design integration by the approach suggested is evaluated by the simulation of fuse material deposition for a simplified version of the selected use case.

Keywords: Additive process simulation | Fused Filament Fabrication | Integrated Design Approach | Robot Programming | Robotic Additive Manufacturing

Abstract: The integration of structural optimization into product design processes has been a focus of extensive research, leveraging advances in computing technology to embed numerical techniques within simulation-driven approaches. Topology optimization, particularly enabled by Additive Manufacturing, has emerged as a powerful tool for generating structurally efficient geometries. However, practical implementation poses challenges, often requiring manual redesign and interpretation of results. To address these issues, this study explores the potential of numerical optimization techniques, specifically parametric and shape optimization, to refine topology optimized structures automatically. The final aim is to develop a systematic workflow integrating these tools to produce ready-to-print geometries with minimal user intervention. The investigation, based on simple geometries resembling topology optimized structures, investigates the tools for simulation-driven design methods utilizing multi-step numerical optimization within an integrated CAD platform, aiming for a direct, efficient, and mathematically-driven design process. Advantages include faster iterations, reduced errors, and independence from user expertise, while challenges such as computational complexity, sensitivity to initial conditions, and need for specific design expertise are acknowledged. The potential further systematic approaches for broader applications, particularly in additive manufacturing and structural engineering, underscore the significance of further research in this area.

Keywords: Computer Aided Engineering | Design for Additive Manufacturing | Design Method | Design Optimization | Finite Element Method

Abstract: Additive Manufacturing processes based on metal deposition are continuously evolving due to the extensive application potentials. Currently, they present a widespread use in manufacturing of large parts and constructions, as well as reparation of damaged components. A promising application is the Remanufacturing of existing components to produce functional design variants. A key phase for its development is the study and control of residual stress and deformations induced by the process. In fact, thermal gradients and cooling rates are more intensive than those related to the other metal additive manufacturing processes and their effect impacts on functional and assembly product requirements. This work provides the study of a laser-based Direct Metal Deposition process, supported by numerical simulation and experimental validation. The aim is to set up a framework for reliable simulations to drive the design of high performance components, which are optimized with respect to both product and process requirements. Process planning and deposition strategies highly affect heat dissipation and thermal cycles, thus, predictive techniques can be embedded in integrated product-process design approaches to avoid flaws and contain components shrinkage and deformation. The process is developed by building specific specimens, performing thermo-mechanical simulations, and comparing 3D capturing result and computed result. The simulation phase can thus be considered as a key step to structure a Design for Additive Remanufacturing workflow. Further developments concern the application of such approaches to the design of high performance components to be produced by Directed Energy Deposition process.

Keywords: Direct metal deposition | Distortion | Finite element analysis | Metal additive manufacturing | Process simulation

Abstract: Within the road to decarbonization scenario, it becomes increasingly central to analyze the sources of emissions from different perspectives and select the more sustainable design approach for the development of new products. Among many sectors, lightweighting can reduce costs related to energy and fuel consumption. Potentially, it is also possible to reduce emissions, both for air and land transport, especially considering vehicles in the context of electrification and green transition. This paper provides an approach for the quantitative estimation of CO2 emissions along the lightweight design of vehicles components. The approach is based on a Life Cycle Assessment (LCA), which includes aspects ranging from product design and production to the use phase, and possible upgrading and recycling. Two lightweight design strategies are considered, using either conventional or unconventional technologies, which are respectively based on Design for Machining and Design for Additive Manufacturing. These methods can be scaled in high-end sectors, as both are characterized by high flexibility and customization, which allow the implementation of lightweight designs for small batch sizes. An automotive component is used as a case study, performing the product-process design based on Computer-Aided Technologies (CAX) for both approaches. The CO2 assessment is performed, considering all the drivers relating to the stages of the product life cycle. Additive Manufacturing is confirmed as more energy intensive, but the additional mass saving over the vehicle use phase returns emissions reduction compared to the whole life cycle.

Keywords: Computer Numerical Control | Environmental sustainability | Greenhouse gas emissions | Lightweighting | Powder Bed Fusion | Product-process design

Abstract: The present work describes an automotive component design optimization process through a systematic approach. The redesign aims to improve product performance by Powder Bed Fusion metal Additive Manufacturing. The approach allows to match Topology Optimization and Design for Additive Manufacturing by exploiting benefits provided by CAD platforms that integrate CAD, CAE and CAM tools. The Systematic Concept-Selection-Based Approach aims to make redesign simple and effective, allowing design solutions exploration while containing product design lead time. Topology Optimization is the key phase to achieve lightweight design by a double-level optimization approach. In particular, the technique is setup to produce different design variants, whose subsequently undergo a Trade-off study to perform the concept selection step. Finally, one final redesign occurs and a design refinement step is performed to achieve product optimization. The case study is a high performance internal combustion engine piston, which has been redesigned to be produced by Selective Laser Melting process with benefit of weight reduction.

Keywords: Automotive | Design for additive manufacturing | Design method | Re-design | Topology optimization

Abstract: Additive manufacturing is even more capturing the interest of vehicle manufactures. Its adoption enables design potentials such as parts customization, lightweighting or functional integration. Deep adoption of additive manufacturing and integration of topology optimization design techniques enable the calculation of light components, while additive manufacturing makes it feasible by adding subsequent layers of material. Design for additive manufacturing guidelines address these challenges by enabling the build of such complex shapes thanks to parts consolidation and features integration. Several prototypes of such lightweight design concerning chassis, body, and structures have been provided, but the lack of structured and objective approaches limits the application in normal production. This work integrates Key Performance Indexes (KPIs) into the Design for Additive Manufacturing (DfAM) approach for an effective adoption of selection of trade-off studies for the selection of best product variant and process setup. The trade-off involves KPIs related to structural product requirements and laser Powder Bed Fusion process cost estimation, to return functional components that address the best ratio between weight reduction and expected manufacturing cost. Proof of the method effectiveness and its application to lighten real components is demonstrated by applying the approach to reduce the weight of a steering support system for a Formula SAE race car. The objectivity of the trade-off promotes the extensive adoption to other vehicle components for substantial fuel efficiency improvement and emissions reduction perspectives.

Keywords: 3D printers | Cost estimating | Economic and social effects | Emission control | Integration

Abstract: In the Industry 4.0 scenario, additive manufacturing (AM) technologies play a fundamental role in the automotive field, even in more traditional sectors such as the restoration of vintage cars. Car manufacturers and restorers benefit from a digital production workflow to reproduce spare parts that are no longer available on the market, starting with original components, even if they are damaged. This review focuses on this market niche that, due to its growing importance in terms of applications and related industries, can be a significant demonstrator of future trends in the automotive supply chain. Through selected case studies and industrial applications, this study analyses the implications of AM from multiple perspectives. Firstly, various types of AM processes are used, although some are predominant due to their cost-effectiveness and, therefore, their better accessibility and wide diffusion. In some applications, AM is used as an intermediate process to develop production equipment (so-called rapid tooling), with further implications in the digitalisation of conventional primary technologies and the entire production process. Secondly, the additive process allows for on-demand, one-off, or small-batch production. Finally, the ever-growing variety of spare parts introduces new problems and challenges, generating constant opportunities to improve the finish and performance of parts, as well as the types of processes and materials, sometimes directly involving AM solution providers.

Keywords: classic cars | component reproduction | Industry 4.0 | original equipment manufacturer (OEM) | rapid tooling | replacement parts | restoration | reverse engineering

Abstract: Metal Additive Manufacturing technologies provide many advantages among industrial sectors. Most applications exploit design freedom for functional design enabled by Powder Bed Fusion processes, while Directed Energy Deposition systems are mainly restricted to the construction of large parts and reparation of damaged components. Nevertheless, the latter provide not only high deposition rates, but also high flexibility, and the possibility to process multi-materials, to grade and combine their characteristics for enhanced features and performance. Therefore, a rising application is the remanufacturing of existing components to produce functional design variants. Those parts can integrate different features and materials through direct deposition of metals over bounded areas. This work concerns the development of a Design for Additive Remanufacturing methodology for existing components with improved performances to be produced by the laser-based Direct Metal Deposition process. It relies on the use of CAD platforms for the integrated design of products and the associated processes. The design approach is based on the integration of CAE structural analysis and Topology Optimization, to define the location and the morphology of deposited structures. The design of an automotive suspension arm with enhanced performances is the use case to demonstrate the effectiveness of the approach, which could be extended to the remanufacturing of several bodies and chassis automotive subsystems.

Keywords: Design for Additive Manufacturing | Finite Element Analysis | Hybrid Manufacturing | Laser Metal Deposition | Remanufacturing | Topology Optimization

Abstract: Additive manufacturing is even more capturing the interest of vehicle manufactures. Its adoption enables design potentials such as parts customization, lightweighting or functional integration. Deep adoption of additive manufacturing and integration of topology optimization design techniques enable the calculation of light components, while additive manufacturing makes it feasible by adding subsequent layers of material. Design for additive manufacturing guidelines address these challenges by enabling the build of such complex shapes thanks to parts consolidation and features integration. Several prototypes of such lightweight design concerning chassis, body, and structures have been provided, but the lack of structured and objective approaches limits the application in normal production. This work integrates Key Performance Indexes (KPIs) into the Design for Additive Manufacturing (DfAM) approach for an effective adoption of selection of trade-off studies for the selection of best product variant and process setup. The trade-off involves KPIs related to structural product requirements and laser Powder Bed Fusion process cost estimation, to return functional components that address the best ratio between weight reduction and expected manufacturing cost. Proof of the method effectiveness and its application to lighten real components is demonstrated by applying the approach to reduce the weight of a steering support system for a Formula SAE race car. The objectivity of the trade-off promotes the extensive adoption to other vehicle components for substantial fuel efficiency improvement and emissions reduction perspectives.

Keywords: Additives | Cost estimating | Economic and social effects | Emission control | Product design

Abstract: The use of Topology Optimization techniques has seen a great development since the last decade. The principal contributor to this trend is the widespread use of Additive Manufacturing technologies to effectively build complex and performant structures over different settings. Nevertheless, the use of Topology Optimization in Design for Additive Manufacturing processes is not simple and research aims to fill the gap between theory and practice by evolving at the same time both approaches, workflows, and design software that allow their implementation. Since a strong connection between methodologies and tools exists, this work proposes a method to assess computer-aided design tools or platforms. This can be applied to sustain the key phase for selection and adoption of the computer-aided tools in industrial settings embracing Additive Manufacturing. The workflow for Topology Optimization implementation, the structure of the proposed evaluation approach, and its application, are presented to demonstrate effective usability. The automotive case study is the redesign of internal combustion engine piston to benefit of metal Additive Manufacturing based enhanced product performance. A preliminary finite element model is defined and a Topology Optimization based redesign is concurrently set up through four different commercial computer-based platforms. The method accounting for the assessment of required operations for the design optimization is applied to perform the tools selection phase.

Keywords: Automotive | Computer aided design tools | Design for additive manufacturing | Design methods | Topology optimization

Abstract: Additive Manufacturing (AM) is a key technology in current industrial transformations thanks to the significant benefits that can bring to high-level sectors. Nevertheless, AM-based design approaches require improvements that are fundamental to exploit the potentials of the technology and reduce the lack of process consistency. This work focuses on integrated Design for Additive Manufacturing (DfAM) approaches for product-process design, to meet both functional and technological targets. The key aspects of process design and issues are summarized and the design method to perform metal AM process optimization is presented. The aim is therefore to minimize process-induced defects and flaws of AM-based manufacturing of metal products, such as residual stress and distortions. The approach consists of industrialization task improvement based on modelling optimization and build optimization sub-phases supported by numerical process simulation. Integration of CAD platforms allows embedding these steps to be performed downstream of the product design, which can be achieved through functional or multifunctional optimization techniques as well (e.g. topology optimization, latticing, graded structures/materials). The design method is finally applied to perform the industrialization phase of a high-performance automotive component. The case study is a formula SAE topology optimized brake caliper to be produced by Selective Laser Melting (SLM) process. Process simulationdriven studies on modelling and build preparation subphases (i.e. orientation definition, supports generation, model distortion compensation) are conducted to support the process design. The study demonstrates the part scale level method's suitability to industrial context to improve industrialization in the redesign of components to be produced by metal AM.

Keywords: Additive manufacturing | Automotive | Design method | Powder bed fusion | Process optimization | Process simulation

Abstract: To implement the CAD platform-based approach of Design for Additive Manufacturing (DfAM) and validate it in a real case, an entire design optimization process of a Formula SAE front brake caliper has been performed, to be printed by Powder Bed Fusion (PBF) process. The DfAM consists in the use of a Ti6Al4V titanium alloy to better resist at high temperatures and a topology optimized shape allowed by the technology to save weight despite the density increase. Structural and thermal behavior has been discussed. DfAM process-specific techniques have been implemented for internal geometrical features and optimized shapes. The design for additive workflow is presented and finally the exploited design approach based on a CAD platform is synthesized.

Keywords: Automotive | Brake caliper | CAD platform | DfAM | Topology optimization

Abstract: Additive Manufacturing based on Powder Bed Fusion processes enables the construction of end-use functional metal components, making it feasible to design several level of geometrical complexity. Nevertheless, the printing process leads to material and shape defects, residual stress and induced distortions on final components that mainly are caused by the high thermal gradients associated to the intense and nonuniform power energy sources used to selectively melt metal powders. In this paper, techniques to reduce or prevent these effects are summarized. The more broadly Design for Additive Manufacturing approach based on the use on CAD platforms for product-process design is the backbone upon this research is based on. Specifically, the work presents a design method to predict drawbacks and improve the industrialization subphase. Laser-based Powder Bed Fusion technique is considered and the implementation and validation of the Selective Laser Melting process simulation is performed in order to support the method. Two case studies are presented. The former demonstrates the simulation implementation feasibility through a CAD platform. The latter validates the simulation results compared to experimental data for further method application.

Keywords: CAD platforms | design for additive manufacturing | industrialization | powder bed fusion | process simulation | selective laser melting

Abstract: The development of additive manufacturing allows the transformation of technological processes and the redesign of products. Among the most used methods to support additive manufacturing, the design can be optimised through the integration of topology optimisation techniques, allowing for creating complex shapes. However, there are critical issues (i.e., definition of product and process parameters, selection of redesign variants, optimised designs interpretation, file exchange and data management, etc.) in identifying the most appropriate process and set-ups, as well as in selecting the best variant on a functional and morphological level. Therefore, to fully exploit the technological potentials and overcome the drawbacks, this paper proposes a systematic redesign approach based on additive manufacturing technologies that integrate topology optimisation and a tool for selecting design variants based on the optimisation of both product and process features. The method leads to the objective selection of the best redesigned configuration in accordance with the key performance indicators (KPIs) (i.e., functional and production requirements). As a case study, the redesign of a medical assistive device is proposed, previously developed in fused filament fabrication and now optimised for being 3D printed with selective laser melting.

Keywords: Assistive device | Design for additive manufacturing | Design method | Design optimisation | Design variants selection | Redesign | Selective laser melting | Topology optimisation

Abstract: Use of Additive Manufacturing provides great potentials to settings focused on high performance products. It allows feasibility of sundry innovative features to completely rethink geometries and shapes and it leads to embrace new design approaches. The enhanced design freedom can be exploited to optimize products, using techniques such as topology optimization. The study of methods for development of optimized components to be produced by AM becomes therefore fundamental. A framework for the methodological approach to operations to be carried out from the concept model to the printed component has been analyzed and it is clear that issues and research efforts relapse both the global level of the workflow and the local level of singular tasks to be performed. Problems related to management of Design for Additive Manufacturing workflow can be solved with holistic approach, through the use of computer aided integrated tools. The aim of this work is to test the effectiveness at local level of such tools with respect to operations for both design and industrialization optimization, working on an automotive case study. In particular, specific tools for topology optimization, product simulation, printing preparation and process simulation are taken as reference and results obtained with an integrated CAD platform are discussed.

Keywords: CAD based integrated platform | Design for Additive Manufactruing | High performance automotive components | Powder Bed Fusion

Abstract: Collaborative robotics and additive manufacturing are two enabling technologies of the Industry 4.0 manufacturing paradigm. Their synergic integration requires novel and effective design approaches, aiming to the development of new reconfigurable solutions for customised processes and products. This work presents an integrated approach that exploits the capabilities of Cobots to mimic the repetitive and exhausting operator’s movements as well as the competitive advantages offered by additive manufacturing to realize tailored equipment. In particular, the case study shows the development of a customised device for the manipulation of biomedical components by means of a Cobot, which is introduced in a workstation to replace manual operations. Moreover, the flexibility and the effectiveness of a Cobot can be improved thanks to customised devices for gripping and pick-and-place operations based on a specific application. During the development phase, we simulated the assembly process, and tested different options. The final configuration, with conformal circuits and suction cups, can pick, manipulate and assembly the biomedical components, and thanks to a Fused Filament Fabrication technology is additively manufactured. In conclusion, this developed prototypal solution proves the real capabilities offered by integrating Cobots and additive manufacturing for the lean automation of a biomedical workstation.

Keywords: Additive manufacturing | Biomedical components | Collaborative robot | Design approach | Industry 4.0

Abstract: Additive Manufacturing is having a great trend since its implementation possible benefits have been widely discussed and efforts in technology improvements are having impact on process reliability and industrial application. The aims of this work are to analyze the current and forthcoming scenario of methods for the specific development of parts to be produced by metal AM including topology optimization as a basic design step and to demonstrate that systematical design approaches can be introduced in order to better exploit potentials offered by AM implementation. The general framework composed by the main tasks is introduced and discussed. Key factors such as advance in different design solutions exploration, product-related and process-related design constraint implementation in the design phase and method effectiveness in product development lead time minimization are presented. Linear and iterative workflows are described, considering features, decision making points, pros and cons, possible variants and research hints. A strong connection between methods and actual means is highlighted and workflow implementation using standard and integrated commercial tools is considered. Such methods are related to several automotive case studies presented in order to demonstrate their applicability and to show actual results and possible further development..

Keywords: Automotive. | Design methods | DfAM | Topology Optimization

Abstract: The presented paper suggests a design method which seeks to identify the best scheduling of human robot collaborative (HRC) operations with respect to a required safety level. The human behavior along manufacturing scenarios is effectively forecasted through dedicated computer-aided tools. Consequently, this method stresses the usage of virtual environment to replicate both human postures and robot encumbrances over the manufacturing operations. Moreover, it proposes a safety index formulation for HRC systems based on the minimum distance between human and robot (H-R). As results, the approach returns the safety index for every possible combination of H-R operations. Subsequently, a scheduling algorithm suggests the operations sequence depending on the expected value of the safety index, providing an evaluation of the time needed to complete the process. The method is validated on surface control phase involved in post-processing of parts produced by laser powder bed fusion (L-PBF) Additive Manufacturing.

Keywords: Additive Manufacturing | CAD-based methods | Human Robot Collaboration | Safety index | Task scheduling

Abstract: Additive Manufacturing is a widespread technology that may enhance product customization based on specific users’ needs, as in the case of assistive devices. Many chronic physical progressively disabling diseases, but also ageing, may cause severe limitations in daily life, which can be overcome by highly customized aids. Literature shows that the active involvement of the patient in the development of assistive devices through co-design allows for their greater therapeutic effectiveness and acceptance. Therefore, this paper proposes a methodological approach for the development of inclusive assistive devices to support daily activities in persons with disabling diseases of the upper-limb. The approach integrates co-design, standardized tools, and low- and high-tech prototyping techniques and tools, which lead to significant feedbacks from patients. The patients are encouraged to interact with conceptual prototypes through direct 3D CAD modelling and touch screen devices. Assessment tests highlight the suitability of the method to achieve the expected goals.

Keywords: Additive Manufacturing | Assistive device | Co-design | Hand pathologies | Inclusive method | Occupational therapy | Parametric modelling

Abstract: The aim of this paper is to analyze some critical issues in the Design for Additive Manufacturing workflow and evaluate the introduction of CAD platforms as backbone tools to shorten product development time and raise its efficiency. It is focused on the design of components to be printed by Powder Bed Fusion metal Additive Manufacturing. Even though the use of additive technologies firmly joins a CAD mathematical model and the actually printed component, the workflow from the concept to the definitive job may result in many sequential steps which have complex and slow relationships. Currently, at the state of art for the production of components specifically designed to be produced by additive manufacturing, there are issues both with the adoption of STL as interchange files and the not reversible sequence of tasks. For example, if a problem occurs in the part re-design during component industrialization, usually one must restart the work from the beginning. Thus, an improvement of the design workflow that could shorten time to product and improve both product performances and process quality and reliability, is necessary. In particular, the use of CAD platforms that integrates CAD and CAE tools has been investigated. An automotive case study, originally made by traditional subtractive technology (CNC milling), has been re-designed with topology optimization in order to be printed by Selective Laser Melting process with benefit of weight reduction. Design and industrialization tasks have been tested with respect to the selected integrated CAD platform, and potential improvements have been evaluated.

Keywords: Automotive | CAD platform | Design for Additive Manufacturing | Topology optimization