Abstract: The concept of a novel sanitization device specifically designed for helmets used in bike share services is presented in this scientific work. The system uses ozone, a powerful oxidizing agent, to completely remove dust and bacteria from the helmet surface. Throughout the development process, special attention has been paid to the dual initial goals of efficacy in removing dirt and batteries, as well as ease of use related to the device's safety. In fact, today's sharing services are rarely capable of providing adequate disinfection of the tools, which is especially troubling given the most recent years of pandemic caused by Covid-19. The invention of the ozone-based sanitization device addresses the growing concern about hygiene and safety in bike share services. Furthermore, due to its portability and ease of use, the device is a cost-effective and viable solution for use in a variety of settings. A significant contribution to the advancement of sanitization technology and public health is expected with this work.

Keywords: Eco-sustainability design | Hygiene | Innovation | Safety | Sanitation system | Sharing services

Abstract: The design of a product consists of several stages to be carried out in sequence until the result is achieved, some of them are performed trough the help of CAD software. This design step is very rigorous with as little margin for error as possible, and it often goes to make a clean break from other stages that precede it. On the other hand, virtual reality technology is certainly an element of interest within various design areas. One of the most promising uses of this type of technology is in the visualization and review of products in the design process. But in this paper we will see a next step compared to this just described, that is, the application of virtual reality within the design making itself. By delving into the design timeline, we will then go on to explore how this technology can provide support not limited to visualization alone, but extended to modeling, what possibilities can be offered by the realization of three-dimensional surfaces, modeled already at the correct scale, and how these aspects can be efficiently integrated within a methodology, assessing variations in timing and quality of work. We will also try to intercept any downsides to try to get a clear understanding of what possibilities could be offered soon by this technology and whether indeed these types of processes can replace current methods, established for years.

Keywords: Design Methods | Industrial Design | Virtual Reality

Abstract: FDM (Fused Deposition Modelling) is the most popular 3D printing technology worldwide due to its simplicity and low costs. One of the key points of FDM is the need for supporting material to realize the overhanging features. In general, however, both in the case of printing supports with the same material as the part and in the case of printing with soluble supports, there is a high waste of material and a significant increase in the printing time to get the finished part. One of the fundamental parameters for generating supports within the slicer software is the so-called “support overhang angle”, which consists of the maximum achievable angle beyond which the slicer generates supports. The other key parameter in FDM printing is the “layer height”, which directly determines both the quality of the final part, its strength, and the printing time itself. This paper will therefore attempt to investigate the relationship present between “layer height” and “support overhang angle”, bringing some examples of how with proper layer height one can significantly reduce support generation, wasted material and in some cases also printing time.

Keywords: FDM | Layer Height | Overhangs

Abstract: ‘Repair’ in the design process of products can prolong the life cycle of parts: this is substantiated by a few examples that put this ideology into practice. Among many other products, home printers could be a good example, with huge numbers of printers ending up in landfill after a relatively short life; often due to blocked print heads that are either impossible or too expensive to replace. The act of fixing things can both prolong the life of an artifact, and create new values through the process of engagement for its users. However, the prohibitive cost of repair makes it inaccessible or unfavorable this practice for many. In this paper a preliminary approach to Design for Repair is proposed, in order to virtually test an industrial case study and to show a comparison between a product, that was intended to disposal after a failure of some components, and the same product re-designed, by taking into account how to repair parts in easy and effective way. Redesign of parts in some cases can be very effective and the virtual test can be easily reproposed in practice, for industrial products. Advantages in the repair of parts is evident in terms of sustainability and circular economy pursuit. This paper suggests a sequenced method to approach the Design for Repair and provide the virtual model of a re-designed solution that could replace the previous one in order to make the repair of components easy and effective. The economic analysis on the effective convenience of repair faced to the disposal of a product was not developed within this context.

Keywords: Circular economy | Design for Disassembly | Design for Repair | Gearmotor | Sustainability

Abstract: Urban mobility scenarios are constantly evolving, and today’s solutions may not be adequate in the future. Through innovative analysis and design methods encapsulated by the IDeS methodology, it is possible to plausibly hypothesize a number of key scenarios to be analyzed, for which vehicles can be designed in order to solve the main problems. Scenarios such as the steady growth in public mobility, based on the sharing of electric mini-buses at the expense of the privatization of the means of transport, lead to the gradual rethinking of citizens’ needs and the supporting infrastructure. Problems such as the lack of privacy of public vehicles, the efficiency of the infrastructure and recharging modes of e-buses, and autonomous driving are addressed here through methods such as QFD (quality function deployment) and SDE (stylistic design engineering), with the aim of outlining a proposal that, to date, is futuristic but is designed to be concrete and feasible within the next decade. These methodologies were applied to the design of a sustainable urban transport system consisting of an electric mini-bus, effected by rethinking the layout of the interior spaces in favor of areas enabling greater privacy and a mobile recharging system (MBS) capable of offering a new management strategy for the non-stop recharging phase. Through the use of an MBS, which functions as a mobile ‘energy bank’ module that is capable of autonomously reaching a mini-bus in need of recharging and extending its autonomy by connecting and recharging it, the proposed system can potentially be enabled to perform its required service during the day without any need to spend time making intermediate stops for the purpose of recharging.

Keywords: autonomous driving | human centered design | minibus | privacy | range | recharging systems

Abstract: The lifecycle of a product is getting shorter in today’s market realities. Latest developments in the industry are heading towards achieving products that are easy to recycle, by developing further technological advances in raw materials ought to include input from End of Life (EOL) products so a reduction of natural harm could be achieved, hence reducing the overall production environmental footprint. Therefore, the approach taken as a design for environment, a key request nowadays in order to develop products that would ease the reverse manufacturing process leading to a more efficient element recycling for later use as spare parts or remanufacturing. The methodology proposed compares three probable disassembly sequences following a comparison of literature-found procedures between genetic algorithms and as a “state space search” problem, followed by a hybrid approach developed by the authors. Time and evaluation of these procedures reached to the best performing sequence. A subsequent augmented reality disassembly simulation was performed with the top-scored operation sequence with which the user is better able to familiarize himself with the assembly than a traditional paper manual, therefore enlightening the feasibility of the top performing sequence in the real world.

Keywords: closed loop | Disassembly | genetic algorithms | metaheuristic method | optimization | particle swarm optimizer

Abstract: Many industrial technologies are developed to optimize products and bring innovation. In particular, the automotive sector is renewing itself according to the rules of green energy and consumption. This huge change requires a reinterpretation of the models on the market updating them to the present and the future needs of automotive industry. In this paper the best compromise between innovation and tradition is found for the Ford brand that has not yet presented electric cars in the sedan segment. Following the SDE method enriched with Quality Function Deployment (QFD), Benchmarking (BM) and Top Flop Analysis (TPA), it is possible to carry out an innovative project. All these technologies must, however, be ordered according to a specific product allowing the best result for the design process. It is therefore necessary identifying the most common stylistic trends in order to draw the external styling of the vehicle using virtual prototyping techniques. To achieve an innovative result, Augmented Reality (AR) is considered to complete the method substituting the static and expensive procedure of making maquettes.

Keywords: Additive manufacturing | Augmented reality | Benchmarking | Car design | Design engineering | QFD | Stylistic design engineering (SDE)

Abstract: A deep research and analysis of a “critical waste” object has been carried out, understood as a subject that does not fare high on the separate collection and recycling system yet: the cigarette butt. This acknowledged social waste is the first among all the garbage detected everywhere around neighborhoods worldwide, and is therefore the epicenter of a situation so worrying that it is necessary to find a solution concerning the environmental pollution. The present exercise was developed, by means of proper product design methods like TRIZ and QFD driven by DFSS rulings, to conceive of new products and services in order to create incentive for the smokers to lessen the environmental pollution problem. The social implications are about the possibility of modifying the bad habits of the smokers and making the user act consciously towards the environment. Throwing the cigarette-stub in the new collection device, rather than on the ground, enables users to enjoy both moral and economic returns. The “Buttalo” service is aimed to incentivize the population to fight against environmental pollution whilst helping smokers to be conscious about it.

Keywords: benchmarking analysis | Design for Six Sigma (DFSS) | quality function deployment (QFD) | Top-Flop analysis | TRIZ

Abstract: This paper is intended to offer a cue for optimizing a generic disassembly process for maintenance purposes. Through the use of a cutting-edge technology such as augmented reality, a key tool that makes it immediate to tell operators what they need to do, this can be made possible as never before within companies. A first aim of the work is to define the optimal disassembly sequence that can lead to the extraction of a target component of the assembly minimizing the number of parts to be removed, applying two methodologies within the framework of Design for Disassembly. Thus, the most important goal is to show and teach to maintenance technicians which steps they should follow in order to efficiently carry out the repair process built on that sequence so that they can work on a product while learning in parallel what they need to do exactly at the same time. This could be useful in case a component replacement becomes necessary especially because nowadays it is still performed inefficiently and lacks a rigorous logic and methodology aimed at its efficiency in companies.

Keywords: augmented reality | CAD modeling | Design for Disassembly | Industry 4.0 | maintenance optimization

Abstract: Improvements in software for image analysis have enabled advances in both medical and engineering industries, including the use of medical analysis tools to recreate internal parts of the human body accurately. A research analysis found that FDM-sourced elements have shown viability for a customized and reliable approach in the orthopedics field. Three-dimensional printing has allowed enhanced accuracy of preoperative planning, leading to reduced surgery times, fewer unnecessary tissue perforations, and fewer healing complications. Furthermore, using custom tools chosen for each procedure has shown the best results. Bone correction-related surgeries require customized cutting guides for a greater outcome. This study aims to assess the biopolymer-based tools for surgical operations and their ability to sustain a regular heat-sterilization cycle without compromising the geometry and fit characteristics for a proper procedure. To achieve this, a DICOM and FDM methodology is proposed for fast prototyping of the cutting guide by means of 3D engineering. A sterilization test was performed on HTPLA, PLA, and nylon polymers. As a result, the unique characteristics within the regular autoclave sterilization process allowed regular supplied PLA to show there were no significant deformations, whilst annealed HTPLA proved this material’s capability of sustaining repeated heat cycles due to its crystallization properties. Both of these proved that the sterilization procedures do not compromise the reliability of the part, nor the safety of the procedure. Therefore, prototypes made with a similar process as this proposal could be safely used in actual surgery practices, while nylon performed poorly because of its hygroscopic properties.

Keywords: 3D engineering | Cutting guide | FDM | HTPLA | Nylon FDM | Preoperative planning | Sterilization

Abstract: The evolution of innovative and systematic design methodologies over time has widened the design concept involvement from the product development phase, which also includes the production and start-up phases. Literature findings have presented to accomplish a Generative Design (GD) approach through the application of an innovative method called Industrial Structure Design (IDeS), a systematic design method able to discover the customer’s needs and the fundamental technical solutions to obtain a good innovative product, involving the whole organization for this achievement. Nevertheless, there is a social demand for solutions to the dramatic and growing problem of marine pollution from plastic materials, encouraging the designers to conceive a new innovative drone for waste collection at sea. Therefore, this study aims to merge all the most advanced design technologies with IDeS in an integrated way, by generating a structure that can also be adopted to plan the organization of a production company. The approach is validated with the design of the Recovery Plastic Drone (RPD) obtained with the IDeS methodology, combining Design and Product development phases, leading to a better and innovative solution for the market.

Keywords: Design Sea | Generative Design (GD) | Industrial design structure (IDeS) | Plastics Recovery Drone (PRD) | Quality function deployment (QFD) | Stylistic design engineering (SDE)

Abstract: Fused Deposition Modeling (FDM) 3D printing is the most widespread technology in additive manufacturing worldwide that thanks to its low costs, finished component applications, and the production process of other parts. The need for lighter and higher-performance components has led to an increased usage of polymeric matrix composites in many fields ranging from automotive to aerospace. The molds used to manufacture these components are made with different technologies, depending on the number of pieces to be made. Usually, they are fiberglass molds with a thin layer of gelcoat to lower the surface roughness and obtain a smooth final surface of the component. Alternatively, they are made from metal, thus making a single carbon fiber prototype very expensive due to the mold build. Making the mold using FDM technology can be a smart solution to reduce costs, but due to the layer deposition process, the roughness is quite high. The surface can be improved by reducing the layer height, but it is still not possible to reach the same degree of surface finish of metallic or gelcoat molds without the use of fillers. Thermoplastic polymers, also used in the FDM process, are generally soluble in specific solvents. This aspect can be exploited to perform chemical smoothing of the external surface of a component. The combination of FDM and chemical smoothing can be a solution to produce low-cost molds with a very good surface finish.

Keywords: Carbon fiber mold | Chemical smoothing | FDM | PVB | Vapor smoothing

Abstract: Additive manufacturing processes have evolved considerably in the past years, growing into a wide range of products through the use of different materials depending on its application sectors. Nevertheless, the fused deposition modelling (FDM) technique has proven to be an eco-nomically feasible process turning additive manufacture technologies from consumer production into a mainstream manufacturing technique. Current advances in the finite element method (FEM) and the computer-aided engineering (CAE) technology are unable to study three-dimensional (3D) printed models, since the final result is highly dependent on processing and environment parame-ters. Because of that, an in-depth understanding of the printed geometrical mesostructure is needed to extend FEM applications. This study aims to generate a homogeneous structural element that accurately represents the behavior of FDM-processed materials, by means of a representative volume element (RVE). The homogenization summarizes the main mechanical characteristics of the actual 3D printed structure, opening new analysis and optimization procedures. Moreover, the linear RVE results can be used to further analyze the in-deep behavior of the FDM unit cell. Therefore, industries could perform a feasible engineering analysis of the final printed elements, allowing the FDM technology to become a mainstream, low-cost manufacturing process in the near future.

Keywords: Additive manufacturing | FDM | FEM | Linear analysis | Microstructure behavior | RVE

Abstract: This study shows an application of the Design for Six Sigma (DFSS) Methodology in the field of medical engineering. This research aims to demonstrate the application of a systematic design approach in the development of the “Ocane”, an innovative concept of smart cane for visually impaired patients which was thought of in answer to the end user’s needs, deploying an easy to transport, locate, and adjust element with ultrasonic sensors and tactile feedback. DFSS is an analytical design methodology meant to organize project workflow in a sequence of specific steps. Other standardized design procedures such as Quality Function Deployment (QFD) and Stylistic Design Engineering (SDE) have been used to support DFSS in terms of targeting customer requirements and focusing on aesthetics for ergonomics analysis, respectively. First, the QFD process is introduced and applied to gather the final customer needs, completing the analysis with benchmarking and similar-thought products on the market. Afterwards, a description of the DFSS methodology and application to the case study was deployed. Thereafter, the SDE procedure is exposed by identifying the “Ocane” concept and development, and moving towards the completion of an inventive product with a creative design and careful attention to visually impaired clients’ requirements.

Keywords: Assistive technology | Blind people | Design | DFSS | QFD | SDE | Visually impaired | Walking cane

Abstract: The design of an E segment, executive, midsize sedan car was chosen to fill a gap in the market of the Ford brand and to achieve the goal of innovation looking towards the future. Ford has not owned an E-segment flagship sports sedan for years, since the historic 1960s Falcon. Starting from the latter assumption and considering that the major car manufacturers are currently investing heavily in E-segment cars, it is important to design a new model, which has been called the Eagle. This model proposed here is to fill the gap between Ford and other companies that are already producing sport cars for the electric sector and to complete Ford’s proposal. The presented methodology is based on SDE, on which many design tools are implemented, such as Quality Function Deployment (QFD), Benchmarking (BM), and Top Flop Analysis (TPA). A market analysis follows in order to identify the major competitors and their key characteristics considering style and technology. The results are used to design an innovative car. Based on the most developed stylistic trends, the vehicle is first sketched and then drawn in the 2D and 3D environments for prototyping. This result leads to the possibility of 3D printing the actual model as a maquette using the Fused Deposition Modelling (FDM) technology and testing it in different configurations in Augmented Reality (AR). These two final applications unveil the possibilities of Industry 4.0 as enrichment for SDE and in general rapid prototyping.

Keywords: Additive manufacturing | Augmented reality | Benchmarking | Car design | Design engineering | QFD | Stylistic design engineering (SDE)

Abstract: Technology evolution and wide research attention on 3D printing efficiency and processes have given the prompt need to reach an understanding about each technique’s prowess to deliver superior quality levels whilst showing an economical and process viability to become mainstream. Studies in the field have struggled to predict the singularities that arise during most Fused Deposition Modeling (FDM) practices; therefore, diverse individual description of the parameters have been performed, but a relationship study between them has not yet assessed. The proposed study lays the main defects caused by a selection of printing parameters which might vary layer slicing, then influencing the defect rate. Subsequently, the chosen technique for optimization is presented, with evidence of its application viability that suggests that a quality advance would be gathered with such. The results would help in making the FDM process become a reliable process that could also be used for industry manufacturing besides prototyping purposes.

Keywords: Defects | Optimization | Optimized FDM | Printing parameters | Void occurrence

Abstract: Three-dimensional printed custom cutting guides (CCGs) are becoming more and more investigated in medical literature, as a patient-specific approach is often desired and very much needed in today’s surgical practice. Three-dimensional printing applications and computer-aided surgical simulations (CASS) allow for meticulous preoperatory planning and substantial reductions of operating time and risk of human error. However, several limitations seem to slow the large-scale adoption of 3D printed CCGs. CAD designing and 3D printing skills are inevitably needed to develop workflow and address the study; therefore, hospitals are pushed to include third-party collaboration, from highly specialized medical centers to industrial engineering companies, thus increasing the time and cost of labor. The aim of this study was to move towards the feasibility of an in-house, low-cost CCG 3D printing methodology for pediatric orthopedic (PO) surgery. The prototype of a femoral cutting guide was developed for its application at the IOR—Rizzoli Orthopedic Institute of Bologna. The element was printed with an entry-level 3D printer with a high-temperature PLA fiber, whose thermomechanical properties can withstand common steam heat sterilization without bending or losing the original geometry. This methodology allowed for extensive preoperatory planning that would likewise reduce the overall surgery time, whilst reducing the risks related to the intervention.

Keywords: 3D printing | CAD surgery simulation | CASS | CT scan | Cutting guide | Orthopedic reproduction model

Abstract: The present study aims to validate a new research method called IDeS (industrial design structure) through the design of an electric bicycle for everyday city life. IDeS is the latest evolution of a combination of innovative and advanced systematic approaches that are used to set a new industrial project. The IDeS methodology is sequentially composed of quality function deployment (QFD), benchmarking (BM), top-flop analysis (TFA), stylistic design engineering (SDE), design for X, prototyping and testing, budgeting, and planning. The present work illustrates how to integrate the abovementioned design methods and achieve a convincing result. In going through the IDeS method step by step, we compare the different solutions on the market in order to understand which are the best performing products and to understand what is missing on the market. This method allowed us to design a bicycle that is as close as possible to the “ideal bike”, obtained with the top/flop analysis.

Keywords: Benchmarking (BM) | Industrial design structure (IDeS) | Quality function deployment (QFD) | Stylistic design engineering (SDE) | Sustainable design | Sustainable mobility | Top-flop analysis (TFA)

Abstract: This experimental study defines the usage of a computer-aided surgical simulation process that is effective, safe, user-friendly, and low-cost, that achieves a detailed and realistic representation of the anatomical region of interest. The chosen tools for this purpose are state-of-the-art Computer Aided Design (CAD) software for mechanical design, and are the fundamental application dedicated to parametric modeling. These tools support different work environments, each one is for a specific type of modeling, and they allow the simulation of surgery. The result will be a faithful representation of the anatomical part both before and after the surgical procedure, screening all the intermediate phases. The doctor will assess different lines of action according to the results, then he will communicate them to the engineer who, consequently, will correct the antisymmetric issue and regenerate the model. Exact measurements of the mutual positions of the various components, skeletal and synthetic, can be achieved; all the osteosynthesis tools, necessary for the surgeon, can be included in the project according to different types of fracture to perfectly match the morphology of the bone to be treated. The method has been tested on seven clinical cases of different complexity and nature and the results of the simulations have been found to be of great effectiveness in the phase of diagnosis and of preoperative planning for the doctors and surgeons; therefore, allowing a lower risk medical operation with a better outcome. This work delivers experimental results in line with theoretical research findings in detail; moreover, full experimental and/or methodical details are provided, so that outcomes could be obtained.

Keywords: 3D processing | CAD-aided | Customized surgery | Pediatric orthopedics | Preoperative planning | Surgical simulation

Abstract: The study of CAD (computer aided design) modeling, design and manufacturing techniques has undergone a rapid growth over the past decades. In medicine, this development mainly concerned the dental and maxillofacial sectors. Significant progress has also been made in orthopedics with pre-operative CAD simulations, printing of bone models and production of patient-specific instruments. However, the traditional procedure that formulates the surgical plan based exclusively on two-dimensional images and interventions performed without the aid of specific instruments for the patient and is currently the most used surgical technique. The production of custom-made tools for the patient, in fact, is often expensive and its use is limited to a few hospitals. The purpose of this study is to show an innovative and cost-effective procedure aimed at prototyping a custom-made surgical guide for address the cubitus varus deformity on a pediatric patient. The cutting guides were obtained through an additive manufacturing process that starts from the 3D digital model of the patient’s bone and allows to design specific models using Creo Parametric. The result is a tool that adheres perfectly to the patient’s bone and guides the surgeon during the osteotomy procedure. The low cost of the methodology described makes it worth noticing by any health institution.

Keywords: 3D Printing | CAD Modeling | Cutting guides | Pediatric orthope-dics | Preoperative simulation | Surgery and diagnostics

Abstract: Software for image analysis endorsed further developments in the medical area that would accept state of the art reengineering processes to reproduce actual internal organs and structures of the human body. Previous research on FDM produced elements in the medicine field shown important discoveries on orthopedics. Preoperative planning shown to be suitable for additive manufacturing solutions that could help to improve the efficiency on procedures lowering potential risks after surgery. Accurate and well thought planning is necessary to choose the best way for the practice and deliver the best results. Tooling customization has shown to help into achieving this result. Bone-related surgeries require customized cutting guides for better accuracy. The following work aims to deliver the opportunity to use variations of Polylactic acid (PLA) based cutting guides in actual surgery practices by means of sustaining a regular heat-sterilization procedure without compromising its tailor-made characteristics. This would be possible by means of a proved, reliable procedure for obtaining the prototype from traditional CT scan images. As a result, HTPLA material composition and crystallization properties allowed to sustain a sterilization procedure in a way that does not compromise the reliability of the part, nor the safety of the procedure, so prototypes made with a similar process as the proposed one, can be used in actual surgery practices with safety.

Keywords: 3D Engineering | Cutting Guide | FDM | HTPLA | Sterilization

Abstract: Nowadays there is a trend of development of a number of FDM-sourced elements that have improved the ways for fast prototyping. CAE software technologies enabled sharing of knowledge across different sectors in the industry, there are important research findings in the medical area in which FDM implies an interesting and a rather efficient option for surgical procedure assessment; mainstream PLA has been a matter of various studies trying to understand its behavior to its limits, a heat treatment on PLA materials could allow to have different, and more diverse applications. HTPLA is another variation that deserves attention due to its prospective. This material has proven to expand the availability of PLA to different sectors because of its rather ease printability and higher heat-resistance. This study would assess the properties of neat PLA and HTPLA printed with optimized parameters, in addition of an annealing process that would modify its internal structure. Results suggest that HTPLA can resist higher temperatures and stress changes whilst scoring lower elongation and tensile response degrading.

Keywords: Annealing | FDM | HT-PLA | Polymers | Tensile Testing

Abstract: Additive manufacturing technologies have evolved rapidly and steadily over the last decade and they become widely used not only in large, high-level companies, but also in medium-sized industries for both the production of prototypes, mockups, and the production of finished components. Stratasys' patented fused deposition modelling (FDM) technology, or more generally Fused Filament Fabrication (FFF), is by far the most cost-effective additive manufacturing (AM) technology especially if compared to powder technologies such as selective laser melting. It offers an extremely wide range of materials from nowadays mainstream, low-cost polylactic acid to the more advanced carbon fiber PEEK. The use of this technology is usually finalized on the production of prototypes and few case studies of end-use components can be found in the literature. This is due to the difficulties in predicting the final behavior of the resulting component and the presence of defects that can cause unpredictable premature failures in the component. This study focuses on describing how it is possible to reduce the defects present in the component with a careful choice of printing parameters and in particular focus on the effect of the parameter called “line width” and its correlation with the geometry of the printable part. The results would help to make FFF a more reliable process that could be used for obtaining a reliable, industrial production as well as prototype manufacture.

Keywords: FDM defects | Line width | Optimized FFF | Printing parameters

Abstract: This paper presents a study based on Design for Disassembly (DfD) applied to a hydraulic pump through the Disassembly Geometry Contacting Graph (DGCG) methodology. DfD is today very important to reduce the disposal or maintenance costs foreseeable already in the planning phase. One of the key points in reducing costs is reducing time for disassemble each component. Because of that, the disassembly time was considered respect to other fundamental and optimizable characteristics such as: Disassembly costs, operations to be performed, quantity of material, etc. All the operations have been evaluated using the time measurement units (TMUs). The objective of the paper is to minimize the disassembly times required for an operator to separate each single component from the other. The study of accessibility, positioning, strength, and basic time led to a comparison between different disassembly methods in order to produce the optimal sequence. In the end, the validation of the sequence was carried out in an Augmented Reality (AR) environment in order to predict the manual disassembly understanding the possible issues without the need of building the components. Using AR, it was possible to look at the assembly during the design phase in a 1:1 scale and evaluate the chosen sequence.

Keywords: CAD | Disassembly | Sequence | TMU | Virtual Reality

Abstract: In the last decade citizens mobility is changing towards a more environment-friendly, more flexible and more shared way of moving around the city. The objective, now, is to decrease the levels of pollution. Notwithstanding people mobility is based on rapidity, sustainability is becoming always more important. In order to follow the new needs of future customers, the present work is presenting a new approach to design in order to obtain an innovative product with the aforementioned characteristics. The new approach is to combine two innovative methodology to design: The first one is Design For Six Sigma (DFSS) and it is useful to structure the project into five main phases (Define, Measure, Analyze, Design, Validate), systematically; the second one is Stylistic Design Engineering (SDE) and it is dedicated to the aesthetic development of a new product following an engineering structure of all the phases of the work. DFSS and SDE will be applied in the present paper in order to give an answer to the arising problem of the new mobility of the future, providing for a new innovative urban means, matching the different characteristics of an hoverboard and of a kick-scooter. The output of the study, described along the paper, is the adaptability of the abovementioned methodologies and the proposal of a new product concept for the scopes illustrated.

Keywords: BENCHMARKING | DFSS | IDeS | QFD | SDE

Abstract: The present paper is about a family car project that starts from a study of the characteristics of the type of car taken into consideration and from an analysis of the environment carried out through an historical research on the models on the market from the 30s to the mid-90s, and their classification. The market analysis was carried out by answering six questions from the QFD and by developing the tables of relative importance and interrelation through which the most important and the most independent requirements to be attributed to the innovative family project were obtained. The competitor analysis was made through a research on the models currently on the market, the development of the benchmarking, and the what/how matrix from which the final requirements and project objectives were determined. The brand was selected, the budget was drawn up over a 12-month period and the car’s product architecture was defined. The SDE was carried out through an aesthetic analysis of the existing models, the sketches for each type of style and the selection of the final sketches. The development of the product, instead, consisted in the prototyping of a 1:18 scale model of the car through 3D printing.

Keywords: 3D Printing | CAD | QFD | Rendering | SDE

Abstract: Since 3D printing was developed, it became the most promising technique to speed up prototyping in a wide variety of areas across the industry. Rapid prototyping allows the medical industry to customize the surgery procedures, thus predicting its result. Biomedical applications made by medical grade elastic thermoplastic polyurethane (TPU); a non-traditional plastic material which allows to obtain additional benefits in rapid 3D prototyping because of its flexibility and anti-bacteriological capabilities. The aim of this study is to assess the efficacy of TPU polymer, FDM objects sourced from CT scanned 3D surfaces for helping surgeons in preoperative planning and training for increasing environment perception, that is, geometry and feeling of the tissues, whilst performing standard procedures that require complex techniques and equipment. A research was performed to assess the physical and qualitative characteristics of TPU 3D developed objects, by developing a proper SWOT analysis against PLA, a widely used, and cost-effective option in FDM industry. Therefore, giving a proposition opposite to other known modern medical planning techniques and bringing out the benefits of the application of TPU-sourced, FDM parts on professional medical training. As a result, PLA is a reliable, wide-available process whilst TPU’s flexible capabilities improves realism in 3D printed parts. Surgical planning and training with rapid prototyping, would improve accurate medical prototyping for customized-procedures, by reducing surgery times, unnecessary tissue perforations and fewer healing complications; providing experience that other FDM materials like PLA cannot be reached.

Keywords: 3D Printing | 3D Scanner | QFD | Surgical Training | TPU

Abstract: Nowadays, the importance of the concept of “Urban Mining” is growing even more, which consists in searching for raw materials inside objects that have reached the end of their life, instead of “inside nature”. It can be commonly found especially in mechanical and electronic equipment valuable materials, which can be extracted and reused as secondary raw materials. The importance of Design for Disassembly (DfD), that is the central topic of this paper, is increasing because of it brings great advantages in terms of disassembly times of components that have reached the end of life. According to the Disassembly Sequence Planning (DSP), this paper presents an application of several methods derived from literature to a two-way valve, to find optimal disassembly sequences. Different sequences have been compared in terms of disassembly time consuming, by the conversion of operations into disassembly time using accredited methods found in literature. Finally, an application in Augmented Reality is proposed to simulate a practical evaluation of what has been theorised so far.

Keywords: Augmented Reality | CAD modelling | Design for Disassembly | Sequence Planning

Abstract: This work aims to present the application of mechanical modeling software in three dimensions in the medical field, analyzing the procedures used by the engineer to support the orthopedic surgeon in preoperative planning. The first step of the procedure involves CT examinations in patients selected for surgery: DICOM images are managed in post-processing to obtain multiplanar reconstructions of the bone lesion to be treated. The files are then optimized, made shareable and imported into CREO's work platform; this is part of a family of CAD software products for mechanical design, developed by PTC, and is the fundamental application dedicated to parametric modeling. The result will be a faithful representation of the anatomical part both before and after surgical procedure, screening all the intermediate phases. The doctor will assess different lines of action according to the results, than he will communicate them to the engineer who, consequently, will correct and regenerate the model. The method finds its power in the dialogue between engineer and doctor: In complex cases closer collaboration is needed while, for the evaluation of less demanding injuries, the exam could be assigned as a remote project which, once completed, is returned to the medical facility of competence.

Keywords: 3D modeling | Computer aided | Parametric software | Preoperative planning | Surgical simulation

Abstract: Fused Deposition Modeling (FDM) 3D printing technology has widespread in a variety of scientific fields, since rapid prototyping and low-cost investments well meet flexibility of application. Mechanical engineering is taking an essential role in Orthopaedics and Traumatology. As a patient-specific approach and minimally invasive surgeries are progressively needed in today’s medical routines, highly-customized 3D printed devices and surgical instruments represent a milestone in medical equipment. Virtual preoperatory planning and computer aided surgical simulations (CASS) enhance 3D visualization of human anatomy, giving doctors full understanding of traumas and deformities. Custom cutting guides (CCGs) represent the cutting edge of patient-dedicated surgical routines, allowing for a sensible reduction of operative time and risk of human error. While maxillofacial surgery (MFS) has already adopted customized 3D printed tools, pediatric orthopaedics (PO) and general long bones surgery strive to put these devices into common practice. Limitations to a large-scale implementation rely on collaboration with the industrial world, as engineering and designing skills are inevitably demanded. Here displayed is the prototype for a femoral cutting guide designed for a pediatric application of the IOR - Rizzoli Orthopaedic Institute of Bologna. The device was printed in a High-Temperature PLA, supporting common steam heat sterilization and maintaining designed geometry.

Keywords: 3D printing | CAD surgery simulation | CT scan | Cutting guide | Orthopaedic reproduction model

Abstract: The present work is a case study about the application of the methodology named Stylistic Design Engineering (SDE), that is an approach to develop car design projects in the industrial world. For attending this goal, it was chosen the S-segment car products, category that identifies the sport car as today’s Lotus. The inspiration for the project started from the top model in the past years of the car manufacturer Audi, or the Audi Quattro (1980-1991). This model represented all the time the most advanced technology in the automotive world of the house, and the most important thing was the all-wheel drive, therefore with four-wheel drive. In the following pages will be illustrated the summary of the path that led to the final product following the “instructions” of SDE method.

Keywords: 3D Printing | QFD | SDE | Sportcar

Abstract: This work is the outcome of a partnership between the Department of Industrial Engineering of the University of Bologna and the Rizzoli Orthopedic Institute of Bologna. The aim of this collaboration is using medical engineering tools during orthopedic surgeries. This article focuses on the design and construction of a custom-made surgical guide for cubitus varus. The guides are special aids that allow surgeons to perform operations smoothly, to achieve the planned result and to reduce the risk of inaccuracy. They are obtained with an additive manufacturing process that starts from a 3D digital model of the patient's bone obtained from CT scans and allow designing patient-specific templates using specific software as the Creo Parametric CAD. For the proper functioning of the guide the internal shape must correspond to the external profile of the patient's bone. In this way, the tool obtained fits exactly to the bone and it is possible to direct the cutting during surgery in a very specific direction as identified in the preoperative planning phase.

Keywords: 3D Printing | Cutting guides | Pediatric Orthopedics | Surgery and Diagnostics

Abstract: This paper presents a project proposal about the design of an innovative and futuristic transport system that aims to replace highways and major roads with a fast, safe and ecological new arrangement. The aim was to conceive an innovative new infrastructure of transport that fits into a future city scenery. In the current historical period we are invested by fast, frenetic and unstoppable evolution that leads to the continuous replacement of products and technologies that in a few years went from being innovative to become obsolete and outdated. Moreover, this process has inevitably affected the whole world of transport: It has assisted and is still witnessing the replacement of diesel and petrol engines with hybrid and electric ones. These evolution and change have led us into the research and understanding of increasingly innovative technologies such as the ones with zero impact motors or magnetic levitation, which in the near future will probably become a valid alternative, or even the new pioneers of transport around the world. At the beginning, the methodology used for the present case study was adopted to analyze how people used to move in the current period (i.e. 2019-20); then, it was taken into consideration the problems linked to the main means of transport diffused, with clean and green technologies; later, it was carried out a market analysis for each category, with related Benchmarking, in order to find the most significant technical characteristics of each one. According to the emerged results, a concept of an innovative transport system was developed, in order to guarantee the safety and privacy of passengers in addition to other performance items, as high speed or integration with other means. The intention was to create a transport network that could connect many cities with direct and easily practicable routes that could replace highways.

Keywords: Ecological | Future city | Future transport | High Speed | Magnetic Levitation | Safe

Abstract: In the present work the Stylistic Design Engineering (SDE), a structured engineering methodology developed to carry out car design projects, is applied to the creation of a new reliable and robust utility vehicle, also suitable for traveling in the countryside. In particular, the design project aimed at the possibility of launching a new Citroen 2CV that would maintain the lightness and reduced fuel consumption of the previous model but that would combine these characteristics with greater eco-sustainability, thanks to electric drive, and greater comfort for passengers. SDE consists of the following steps: (1) sketches; (2) 2D CAD drawings; (3) 3D CAD models; (4) 3D printed models (also referred to as styling models); (5) Optimization of maquettes through technical objectives. This project deals with the exterior restyling of the Citroen 2CV and was carried out using different technologies and design methodologies that will be further explained in detail, such as the Pininfarina method, the QFD (Quality Function Deployment) and the 6 Sigma method. The work was organized in different phases and in all these phases the quality methodologies mentioned above were used. At first the Citroen style was studied, a fundamental step to better understand the characteristics of the brand and also the main characteristics carried out over the years of the product's life. Subsequently, the freehand sketching phase was carried out, inspired by the considerations made in the previous study phase. This phase continued until a satisfactory form was found by analyzing and discarding the various proposals of the various types of style. Once the definitive proposal was chosen, the definitive three-dimensional shape was obtained and on it it was possible to evaluate proportions and dimensions, also thanks to the rendering software.

Keywords: Benchmarking Analysis | Car Design | Quality Function Deployment (QFD) | Stylistic Design Engineering (SDE) | Top Flop Analysis

Abstract: The life of industrial products is getting shorter due to the rapid evolution of technologies. Because of that, the creation of models that are interested in last part of the product’s life are becoming extremely relevant. In recent years, many investments have been made in the recycling of raw materials and the reuse of End-Of-Life (EOL) products in order to reduce the waste of resources. Strategies of Design for Environment (DfE) have been searched and, for this reason, the Design for Disassembly (DfD) has become a fundamental phase in the product life cycle with the subsequent creation of design techniques aimed precisely at disassembly. Using this methodology, the designer can study and plan the optimal sequence which should be based on countless factors and criteria because there is not a straightforward path or a single combination of operations to follow. This paper describes and compares multiple disassembly methods based on minimum disassembly time with reference to a worm gear reducer. In particular, the component was made entirely on CAD (SolidWorks) and the sequences were pplied in a virtual environment. In this way, it was possible to evaluate different algorithms and obtain the optimal disassembly sequence that minimize the overall disassembly time.

Keywords: CAD | Disassembly | Sequence | TMU | Virtual Reality

Abstract: Beginning from an analysis of all the top types of execution of the hoverboard, a contemporary vehicle for city transportation, inventive concepts were generated to design it. Quality-oriented methodology, just like Quality Function Deployment (QFD) for example, contributed the desires to start from, while through an innovation-oriented methodology, just like Teorija Rešenija Izobretatel'skich Zadač (TRIZ) method, proposals and notions for innovative settings were reached. In practice, while the QFD methodology has a powerfully conceptual appeal, and it is the basis of our analysis, the TRIZ method gives a more innovative thrust and deals the aspects that are strongly constructive and concrete. The matrix of contradictions has been used within the Hill model, and through it, it has been possible to rework the innovative problems, suggested by the analysis of the QFD, in terms of technical contradictions. The main purpose of the following work is to demonstrate how the two methodologies mentioned above, namely the QFD methodology and the TRIZ methodology, can be integrated within a path of development of innovative products, supporting one for the other.

Keywords: contradictions | innovative solution | QFD | TRIZ | urban transportation systems

Abstract: In this work, a structured design method, the Stylistic Design Engineering (SDE), is applied for the construction of a new minivan car, in particular a new city car, which we will call FIAT 600 Omega. The SDE, or Stylistic Design Engineering, is a structured engineering method for carrying out automotive design projects. The SDE method consists of six different phases: (1) Analysis of stylistic trends; (2) Sketches; (3) 2D Computer Aided Design (CAD) drawings; (4) 3D CAD models; (5) Rendering; (6) Solid stylistic model (also called style maquette). This project deals with the external redesign of the Fiat 600 multiple, a small minivan which was very successful in the 1950s and 1960s. SDE is a methodology consisting of various technologies and design methodologies that will be further explained in detail, such as the Pininfarina method, the Quality Function Deployment (QFD) method, Benchmarking (BM), and Top Flop Analysis (TPA). The work was organized according to the different phases. Initially, the Fiat style was studied, in particular the style of the FIAT 600 MULTI PURPOUSE VEHICLE (MPV). This step is essential to better understand the characteristics of the brand and also the main characteristics carried out over the decades. Then we moved on to the freehand sketching phase, based on what we learned in the previous phase of the study. When a satisfactory shape was found for the new car, by analyzing and discarding the different proposals of the various types of style, we proceeded to the evaluation of the proportions and dimensions through two-dimensional drawings and finally we obtained the three-dimensional shape of the new car thanks to 3D CAD software and rendering software. Many advantages in the industrial world SDE takes together with its development. In fact, until the early 2000s, car design and styling was considered quite a craft activity, not a technical or scientific one, mostly based on the great capability of famous car designers and masters, just like Giugiaro, Zagato, Bertone, Pininfarina, Stephenson, Bangle, etc. Then, thanks to the industrial activity of Eng. Lorenzo Ramacciotti, former CEO of Pininfarina Spa and Mechanical Engineer, and also thanks to the academic studies developed at ALMA MATER STUDIORUM University of Bologna, SDE became the object of attention, because it is able to systematize the car design process and reduce costs. With SDE, a good design research or an industrial product development team can complete a car design project, also without the presence of a mentor. Car Design Process finally becomes with SDE a scientific method; Car Design becomes with SDE an industrial method. Industrial needs are nice products made in a short time; SDE is structured to attend these issues. Industrial challenges follow innovation, in shape and functionality; SDE is able to recognize innovation. Industrial benefits can be reached with SDE, ensuring beautiful aesthetic projects are realized systematically and with low costs.

Keywords: Benchmarking | Car design | Citycar | Design engineering | QFD | Stylistic design engineering (SDE) | Topflop analysis

Abstract: "Innovation activities" means all the scientific, technological, organizational, financial and commercial steps aimed at implementing innovation. Some innovation activities are themselves innovative, others are not new, but they are necessary for the implementation of innovation, such as Research and Development not linked to a specific innovation. Innovation has a close reference to the economic market, that is to say with the users of the innovated product: if these are not sufficiently developed they are not able to understand it and appreciate it. Innovation, making the process better, generates greater competitiveness: it is the dream of something better that translates into general well-being. This work presents an innovative hybrid car's design, belonging to the E-segment. The choice of this segment is already innovative in its nature, as despite being currently in strong development, hybrid and electric engines are still little used for large sedans. The method we present in this paper for the car design is also innovative and is called Design for Six Sigma. It is a method used to develop new products, through the determination of customer and market needs and the transformation of these requests into the product generated.

Keywords: Automotive | Bench marking | Car | Design for six sigma | E-segment | Quality function deployment | Sedan

Abstract: Sustainable mobility means a series of services and means of transport designed to reduce traffic, improve air quality and cut energy consumption; it is essential to integrate the various transport systems and encourage the spread of electric vehicles. The European Commission proposes new targets for average CO2 emissions to accelerate the transition to low-emission vehicles. The goal is to reduce emissions by 40% by 2030, in line with the Paris agreements. It is not only a question of replacing private means of transport, but also of encouraging the development of new business models and more efficient use of public and freight transport. The present paper works on six main points: • New standards that help manufacturers to innovate and offer low-emission vehicles on the market • Solutions for sustainable mobility in public systems • Investments for the diffusion of infrastructures for alternative fuels • Revision of the combined transport directive which promotes the use of different means for freight transport • Development of long distance bus connections across Europe • Development of better and better batteries The diffusion of micro-mobility systems requires a general change of context. The city must keep up with technology and become smart, the regulations and all sharing phenomena must be adequate. In 2020, 80 billion objects connected to the world through 1200 satellites are estimated: urban mobility will be greatly influenced and will become a connecting element between the environment and those who live in it. The micro-mobility market in Europe could reach 150 billion dollars by 2030. As the possibilities for use increase, the number of startups for mobility sharing also increases. It is estimated that at the end of 2018 there were 5.2 million subscribers to at least one of the sharing services active in the area, one million more than the previous year. In particular, this project aims to propose an innovative, sustainable and ecological means of transport suitable for everyone and which can be a valid alternative for getting around the city.

Keywords: Benchmarking Analysis | Industrial Design Structure (IDeS); Car Design | Quality Function Deployment (QFD) | Stylistic Design Engineering (SDE); future mobility

Abstract: This paper presents a design proposal of a future family car. The target audience of this application are families with children, so that different customer needs must be satisfied, like as good performances, reliability, spaciousness, eco-sustainability, safety and regulations for infants. The reference segment of the family car is the C / E of the Stan-dards ISO 3833: 1977. The first methodology used in this paper is the QFD, to determine the fundamental characteristics of our proposal. Then, with a Benchmarking analysis, we highlighted the most advantageous – top – and most disadvantageous – flop – solutions in terms of our product. The brand that emerged as the most suitable to meet the most influential characteristics from a customer perspective is Volkswagen. Subsequently, we proceeded using the tool of the SDE. Some features of different stylistic trends have been analyzed and merged to present our 7-seats, 4-wheel drive and 2-volume family car proposal, named “T-Golf”.

Keywords: Benchmarking Analysis | Car Design | Quality Function Deployment (QFD) | Stylistic Design Engineering (SDE)

Abstract: The work presented is a case study about the application of the methodology named Design For Six Sigma, which involves the concepts of Benchmarking and QFD analysis, applied to different devices/appliances, without having the target of the creation of a specific final product, but trying to outline a prototype of an innovative domotic house, where every device is connected to the main network and can communicate with the others. Four categories of products were analyzed: robot vacuum cleaner, smart refrigerators, domotic ovens and robot lawnmowers. Today these devices are very smart and technologically advanced but cannot co-operate for the realization of a connected system; which could happen thanks to the increasing use of Google Home and Amazon Alexa devices. In the following pages will be illustrated all the process described above comprehensive of the house project realized on SolidEdge and rendered on KeyShot.

Keywords: Benchmarking | Design For Six Sigma | Domotics | House of quality | QFD

Abstract: Given the general subject “Automotive Design” as starting point of the research, it was decided to focus the present paper on a particular segment of cars: the A segment, which is usually known as City Car. Before even starting to research about the City Car world, it was scheduled the work phases in a general way and after that, organizing time week by week to be sure it wouldn’t be run out of time before the complete ending. A Road Map was used as a graphic method to better visualize the path to follow during the project, in order to stay focused and always know and be ready for the next step. Two major moments were identified: a project set up, followed by the project development. The Project Set Up includes some preliminary analysis, to better understand the environment in which it is operating, only then it was be able to start focusing on the concept for our new car. Once defined the entire concept, and all the requests that should be to satisfied, the budget was outlined, instrument needed to cover the costs of design and production of the entire car. The Project Set Up comes to an end after the last phase of styling, which include a series of propositions concerning the aesthetic of the shell. Next, the developing of the project was taken on. This phase includes the 3D modelling via software, followed by the optimization of the model concerning the aerodynamic and the overall form. Once all the details concerning the 3d model were defined, it was time to proceed on prototyping the entire car via additive manufactory.

Keywords: Benchmarking Analysis | Industrial Design Structure (IDeS); Car Design | Quality Function Deployment (QFD) | Stylistic Design Engineering (SDE)

Abstract: This work is focused on the study of 3D prints applied in the orthopedic-pediatric field. The focus is therefore on all the processes that lead to obtaining 3D bone printing starting from the three-dimensional digital CAD model. Specifically, the case study concerns patients with flat foot pathology from tarsal synostosis. The final result of the printing process is a three-dimensional bone model reflecting the original anatomical structure. This is a useful tool for surgeons who can carry out a preventive analytical evaluation of the relative intervention methods. 3D printing can be useful both in the preoperative planning phase and during the operation. Depending on the case, it may be more convenient to use one material than another. For this reason, another goal set by this work concerns the study of materials used for 3D printing of bones.

Keywords: 3D Printing | Diagnostics | Pediatric Orthopedics | Surgery

Abstract: High-Speed Trains are defined as the “transport of the future” thanks to three main characteristics: safety, capability and sustainability. It is an environment friendly solution because it relies on electric energy, which can be fully produced from renewable sources, and it pollutes less compared to other transport systems. In fact, in comparison with automobiles and airplanes, High-Speed Trains generate 9 and 6 times less carbon dioxide respectively; and in terms of consumption per kilometer, it consumes respectively 6 and 4 times less. The first ever High-Speed Train was born in Japan and it began service in 1964 under the name of “Shinkansen”. The Japanese railway system has proved throughout history the efficiency and safety of this solution, becoming a model for the development of high-speed networks in other countries. Train designs vary depending on existing railways, geography and market requests. Bogies were born as simple supports for the coaches, provided with wheels and brakes, but with technological innovations, modern models contain electric engines, sensors and security devices. In this work, a new bogie was proposed following the rules of Design for Six Sigma (DFSS), which holds the main advantages of the models provided on the current market by the competitors.

Keywords: Design Engineering | Design for Six Sigma (DFSS) | High-Speed Train | Train Design

Abstract: The present work shows how 3D models extracted from a computerised tomography (CT) scan can be processed to be 3D printed into 1:1 orthopedic scale models, which find unquestionable utility in pre-operative surgical planning. Relying on the CAT-CAD methodology, which produces a 3D surface called “mesh” from diagnostic images of body parts, the CAD-AM process elaborates a volumetric bone model which a cost-efficient FDM printer can work with. The suitable materials for these applications are PLA polymers, due to their thermo-mechanical properties, affordability and ecological sustainability; these anatomic 3D printed models allows surgeons to accurately see bones injuries and trauma, resulting in a minimisation of risk and a much more flowing doctor-patient communication. Furthermore these 3D printed objects can be manufactured with specific density in order to simulate bone tissues, resulting in a useful tool through which experienced surgeons can pass on their knowledge to medical students at a very reasonable cost, overcoming the glaring limitations of two-dimensional images provided by CT scans. Here represented is a 3D printed 1:1 scale model of a femur donated to the Bone Bank of IOR-Rizzoli Orthopaedic Institute in Bologna.

Keywords: CT scan | FDM printer | Orthopaedic Reproduction Model | PLA polymer

Abstract: Design for Assembly is a strategy of design aimed at minimising product cost through design and process improvements. It led to a revolution in the manufacturing industry, resulting in reduced product costs, improved quality, shorter time to market, lower inventory, fewer suppliers and many other improvements. DFA is the method of design of the product for ease of assembly and in this context this paper presents an application of the strategy to a virtual case study represented by a two-way relief valve modelled by CAD. The aim of this paper was to test some DFA methods proposed by the literature and search for an efficient assembly of the virtual two-way relief valve reproduced by CAD, then verifying its assembly effectiveness. Some evaluation methods proposed by literature about the optimisation of design efficiency have been applied to the case study and this led to reconsider the design of some parts of the product. A final new design for the valve is proposed and the evaluation methods applied have been tested again on the new solution, in order to validate the results. A comparison between the original valve and the new version proposed by the authors has been made, in order both to check the feasibility of the new valve and in order to check the evaluation methods proposed.

Keywords: CAD | DfA | Optimization

Abstract: The present study wants to bring to light a new type of crutch designed for a chronic patient with perennial limited mobility, who must use this support every time a move is needed. The main purpose of the project consists in recommending a correct use of the crutch through technology, limiting the damage normally caused by a bad use of crutches and giving a support both for the patient and for the doctor. All of the features of the crutches were defined through relationship matrices and a benchmarking, which helped us for defining the requirements; other important features were defined, taking a look to the technological progresses applied to new, patented crutches. The result is a sensorized crutch, functional and oriented to meet the user's needs in order to prevent an incorrect use of the support avoiding the growth of other pains.

Keywords: Analysis | Benchmarking | Crutch | Industrial Design Structure (IDeS) | Matrix of relative dependence | Matrix of relative importance | Medical prosthesis mobility | Patient | Project | Sensors | Tool

Abstract: Both economical and environmental aspects significantly influence the design process since the early phases of preliminary design. The total Life Cycle Assessment (LCA)and the End Of Life (EOL)of products have to be defined in the early design phase too. For industrial products that are not addressed to automatic manufacturing processes, the LCA and the EOL are an hard issue. However, the EOL of products, meant as recycling or reusing of parts, can be evaluated by means of the disassembly easiness of joints assembling the product, even when the production process is subject to an important contribute of workmanship. To facilitate this approach, a useful method is proposed in this paper to evaluate the disassembly of products, also of handcrafted products, in order to optimize the design process in the early preliminary phase. The method quantitatively evaluates an index, referred as the Disassembly Index, that describes the attitude of a product to be disassembled in order to recover its components (or its partial subassemblies). A case study is proposed to evaluate the disassembly attitude of structural subassemblies of a sailboat. The comparison to a standard product is proposed in order to test the sensitiveness of the Disassembly Index to automatic manufactured products. As conclusion, good performances to support the EOL evaluation of non conventional products have been demonstrated and a huge sensitiveness of the Disassembly Index to destructive and non destructive procedures is evidenced in the paper.

Keywords: Design for disassembly | Handcrafted product | Non-destructive disassembly & reusing of parts

Abstract: Today's market drives companies to change, adapt, and compete. Many consumers are increasingly looking at price, without sacrificing quality. In order to be attractive to the customer, companies must be able to offer the required quality at the lowest possible price. The life cycle of many products has been shortened compared to the past because now technologies are evolving faster. For these reasons, it is important that companies reevaluate all the operations that are carried out within them, to optimize them and eventually adopt new technologies if they offer interesting opportunities. In this discussion, we first study the design for disassembly, a technique that can bring several advantages during the life cycle of a component, offering the possibility of reducing time and cost of disassembling a product, and better reuse of the different materials of which it is composed. Subsequently, augmented reality is discussed, and how this technology is exploited in the world, especially in the industrial sector. During the work, we discuss a case study, with the gearbox being the object of analysis. This allows us to apply the theoretical concepts illustrated in a concrete way, allowing for a better understanding of the topics.

Keywords: Augmented reality | Computer aided design (CAD) | Design for disassembly | Gearbox

Abstract: Our purpose is to develop the preoperative diagnosis stage for orthopedic surgical treatments using additive manufacturing technology. Our methods involve fast implementations of an additive manufactured bone model, converted from CAT data, through appropriate software use. Then, additive manufacturing of the formed surfaces through special 3D-printers. With the structural model redesigned and printed in three dimensions, the surgeon is able to look at the printed bone and he can handle it because the model perfectly reproduces the real one upon which he will operate. We found that additive manufacturing models can precisely characterize the anatomical structures of fractures or lesions. The studied practice helps the surgeon to provide a complete preoperative valuation and a correct surgery, with minimized duration and risks. This structural model is also an effective device for communication between doctor and patient.

Keywords: 3D-printing | Additive manufacturing-modeling | CAT scan | Diagnosis | Orthopedics | Surgery

Abstract: With this article, we intend to set the first strategic phase of the product development process, that is to say the one related to the conceptual project. In particular, this work refers to the installation of the project of an innovative, green, sustainable means of transport based on renewable energy, to move to the center of medium and large cities. The discussion presented presents a series of cutting-edge methods, in series of logical use, in order to make both strategic and technical decisions. Among the inputs of the methods, we will have an analysis of customer needs, competitive analysis, a series of technological objectives (or performances) as a result of the work in progress. In particular, we will first use the quality distribution method (QFD), then the method of analyzing competition through Benchmarking to identify the quantitative requirements that will give us the opportunity to create an innovative product, enhanced by a Top-Flop analysis to determine the number of requirements of the best product on the market, which will be the limit to be overcome to embody innovation in a new project. As for the QFD, the input values are the customer's requirements, obtained with the "Six questions" method; then applying an interrelationship of the QFD matrix, the outputs of the method described above were obtained, representing the classification of all the various urban transports, classified according to user preferences. The application of the competition-oriented method of competition analysis through the use of Benchmarking is applied after the QFD. The inputs are the quantitative specifications, that is the performance, of all the hoverboard models of all the brands on the market. The output, however, is a comparison graph that contains all the performance values for each model. Other inputs will be table data, other outputs, values (or ranges of values) for each performance, so as to obtain a technical specification with quantitative objectives to obtain an innovative product.

Keywords: 3D & hoverboard | Design engineering | Quality distribution method | TRIZ

Abstract: In an increasingly competitive business world, the “time to market” of products has become a key factor for business success. There are different techniques that anticipate design mistakes and launch products on the market in less time. Among the most used methodologies in the design and definition of the requirements, quality function deployment (QFD) and design for Six Sigma (DFSS) can be used. In the prototyping phase, it is possible to address the emerging technology of additive manufacturing. Today, three-dimensional printing is already used as a rapid prototyping technique. However, the real challenge that industry is facing is the use of these machineries for large-scale production of parts, now possible with new HP multi-fusion. The aim of this article is to study the entire product development process taking advantage of the most modern models and technologies for the final realization of a case study that involves the design and prototyping of an innovative multifunctional fan (lamp, aroma diffuser and fan) through the Multi Jet Fusion of HP. To begin with, issues related to the DFSS, the QFD and their application to identify the fan requirements are explored. Once the requirements have been defined, the modern CAD design systems and the CAE systems for the validation of the case study will be analyzed and applied. Finally, HP’s Multi Jet Fusion methodology and design rules for additive manufacturing will be analyzed in detail, trying to exploit all the positive aspects it offers.

Keywords: CAD | CAE | Design for additive manufacturing | Design for six sigma | FEA | Multi jet fusion | Product development | QFD | Rapid prototyping

Abstract: In an increasing number of aggressive enterprise world, “time to market” concerning products has come to be a solution element because of enterprise success. There are exceptional techniques so expect layout mistakes or open products concerning the need between much less time. Among the most used methodologies in the design and setting about stability the requirements, Quality Function Deployment (QFD) and Design for Six Sigma (DFSS) execute remain used. In the prototyping phase, such is feasible in imitation of tackle the rising science regarding additive manufacturing. Today, three-dimensional stamping is in the meanwhile used as a rapid prototyping technique. However, the actual challenge that enterprise is going through is the use of these machineries for large-scale production about parts, at last viable along current HP Multi fusion. The aim of this article is to study the interactive design and engineering applied to the entire product development process taking advantage of the most modern models and technologies for the final realization of a case study that involves the design and prototyping of an innovative multifunctional fan (Lamp, Aroma Diffuser and fan) through the Multi Jet Fusion of HP. To begin with, issues related to the DFSS, the QFD and their application to identify the fan requirements are explored. Once the requirements have been defined, the modern CAD design systems and the CAE systems for the validation of the case study will be analyzed and applied. Finally, HP’s Multi Jet Fusion methodology and design rules for additive manufacturing will be analyzed in detail, trying to exploit all the positive aspects it offers.

Keywords: CAD | CAE | Design for additive manufacturing | Design for Six Sigma | FEA | Multi jet fusion | Product development | QFD | Rapid prototyping

Abstract: Stylistic Design Engineering (SDE) is an engineered method developed for creating a structured way to realize Car Design Projects. SDE is composed by the following steps: (1) Stylistic Trends Analysis; (2) Sketches; (3) 2D CAD Drawings; (4) 3D CAD Models; (5) Rendering; (6) Solid Stylistic Model (defined also styling maquettes). In the present paper, SDE is applied to a new SUV, in particular to a new possibility of launching a new FIAT Campagnola, an off-roader that was very successful in the 1950s -1970s. This project deals with the exernal redesign of Fiat Campagnola. It has been carried out using various design technologies and methodologies that will be further explained in details, such as the Pininfarina method, the QFD (Quality Function Deployment) method, Benchmarking e Top Flop analysis. The work has been organized according to different phases. At first it has been studied the Fiat style, an essential step to understand better the features of the brand and also the main characteristics carried out during the decades. Later we carried on with the phase of the freehand sketches, being inspired by what was previously learned in every single step of study. This phase continued until a satisfactory form was found by analyzing and discarding the various proposals of the various types of style. Once the proposal was choosen, then the three-dimensional shape was obtained and on which it was possible to evaluate proportions and dimensions, also thanks to rendering software. All the analysis methodologies required for the quality of the project mentioned before have been used during all these phases.

Keywords: Benchmarking | Car design | Design engineering | QFD | Stylistic Design Engineering (SDE) | SUV

Abstract: The present work is a case study about the application of the methodology named Stylistic Design Engineering (SDE), that is an approach to develop car design projects in the industrial world. For attending this goal, it was chosen the E-segment car products, in particular following the necessity to fill a gap in the Alfa Romeo's market, which offers currently only models in A, B, SUV and coupe´ segments and needs a kind of model that could be successful in the market. In fact Alfa Romeo does not own a E-segment sport sedan flagship car model for years now (the last one was the 166). Based on this assumption and the fact that the largest car manufacturers are currently investing heavily on E segment cars, it was interesting to think about a new Alfa Romeo flagship model, maybe named with glorious name Alfetta. In the following pages will be illustrated the summary of the path that led to the final product following the instructions of SDE.

Keywords: Car design | Design engineering | Stylistic design engineering (SDE)

Abstract: Both economic and environmental aspects significantly influence the design process since the early phases of preliminary design. The total Life Cycle Assessment (LCA) and the End of Life (EoL) of products have to be defined in the early design phases too but, for industrial products that are not feasible to automatic production, they are hard issues. However, the EoL of products can be assessed by evaluating the disassembly of joints assembling the product, even when the production process is subject to an important contribute of workmanship. In this paper, a useful method is proposed to analyze the disassembly plant of products, in order to optimize the design process in the early preliminary phases. The method quantitatively evaluates a Disassembly Index that describes the attitude of a product to be disassembled. A case study describes the disassembly attitude of structural subassemblies of a sailboat. In order to test the applicability of the model described to both manual and automated disassembly, a further application of the method is proposed on a Computer CPU. As result, the model demonstrated good sensitiveness to the testing of products quite different for dimensions, number of components, manufacturing processes and, in all cases, it quantified the disassembly easiness with good relevance.

Keywords: disassembly | handcraft | non-destructive | quantitative | reusing

Abstract: Considering the progressively expansive trade world, "time to market" of productions and goods has turned into a key element for business accomplishment. There are diverse practices that antedate design faults and unveil products on the market in minus time. Among the most used methods in the design and explanation of the necessities, quality function deployment (QFD) and design for Six Sigma (DFSS) can be used. In the prototyping stage, it is probable to address the emergent technology of additive manufacturing. Today, 3D printing is employed as a quick prototyping technique. Nevertheless, the tangible task which industry is fronting is the adoption of these machines for large-scale production of components, which is now possible with new HP multi fusion. The goal of this paper is to illustrate the entire product development process taking advantage of the most modern models and technologies for the final realization of a case study that involves the design and prototyping of an innovative multifunctional fan (lamp, aroma diffuser, and fan) through the multi jet fusion of HP. To begin with, issues related to the DFSS, the QFD and their application to identify the fan requirements are explored. Once the requirements have been defined, the modern CAD design systems and the CAE systems for the validation of the case study will be analyzed and applied. Finally, HP's multi jet fusion methodology and design rules for additive manufacturing will be analyzed in detail, trying to exploit all the positive aspects it offers.

Keywords: CAD | CAE | Design for additive manufacturing | Design for Six Sigma | FEA | Multi jet fusion | Product development | QFD | Rapid prototyping

Abstract: The present paper begins a series of features considered essential to the success of an innovative means of transport in the cities: the hoverboard. These features are obtained from a previous QFD analysis and are the starting point for a further TRIZ analysis that aims to obtain innovative technical solutions, in order to manage the transition from conceptual design to construction design. Through a hill model, the technical problems have been reformulated in terms of technical contradictions, and through the tools of TRIZ, as the matrix of contradictions, have come to obtain general resolution principles. From these general principles of resolution, innovative solutions for the construction of the innovative transport vehicle have been devised. These innovative solutions will be the starting point for a further engineering process that can be developed into further work.

Keywords: City transportation means | Contradictions | Hill model | Innovative solution | QFD | TRIZ

Abstract: Over the last years, good strategies for efficient manufacturing were considered increasing the volume of production and reducing the time and costs. Emerging design strategies as the Design for Environment and life cycle assessment, the Design for Sustainability, the Design for Disassembly moved the focus to conceive a product by taking care of all the effect that its use can cause to the economy, to the society and to the environment, also at its disposal. In this context, design strategies have to be enhanced in order to integrate innovation with sustainability and social care. Thus, the horizon for strategic manufacturing has to pay particular attention to the effects that it could produce to the surrounding environment. This way, some manufacturing techniques that could be considered obsolete in terms of sustainability awareness, but that are not yet ready to be replaced by advanced available technologies, need a requalification in order to be collocated in the current scenario. In this paper, the open moulding technique has been discussed in order to update the current manufacturing technique to meet the emerging sustainable strategies. Through the integration of QFD and TRIZ an innovative design method have been assessed to enhance the manufacturing process by means of computer aided engineering devices. PrinterCAD is a project that aims to manage additive and subtractive techniques, applied to complex and large-scale products, by means of an open source software with an integrated module, in order to enhance the CAD, CAM and slicing for the 3D printer’s languages intercommunication.

Keywords: CAD | CAM | Hybrid manufacturing | Open source | QFD | TRIZ

Abstract: The planning activity relative to physical items, environment, and services that adapts to optimize social, economic, and ecological impact is the target of sustainable design. Quality Function Deployment (QFD) achieves product design by choosing and defining factors that can be qualitatively argued. The aim of design is to match needs in new and innovative ways. In this perspective, the QFD aims to evaluate the quality of a design process. TRIZ is a design methodology that aims at defining and overcoming some critical issues that can affect the development of a product, by means of potential innovative solutions. In this paper, QFD and TRIZ analysis were adopted in order to validate a design method for direct open molds by means of a new strategy: hybrid manufacturing can reduce production time, use of material, and energy and waste consumption, employing subtractive and additive techniques efficiently combined.

Keywords: Additive | direct open mold | hybrid manufacturing | QFD | subtractive | TRIZ

Abstract: The aim of this article is to apply some design methodologies to define, as a first objective, an optimized technical specification and then, as a second objective, to manage the transition from conceptual design to construction project of an innovative means of urban transport, meeting the needs of 'renewable energy' requirements, which then decline into this new urban vehicle formed by a hoverboard and an electric scooter. The first part of the article is focused on the conceptual design of the means by using methodologies such as the Quality Function Deployment (QFD), applied in the first phase of the work to compare some of the most popular electric scooters on the market; we then used a typical method for product marketing, i.e., the decision-making process driven by the analysis of benchmarking, suitable for quantitatively organize competitive analysis and choosing innovation targets; finally, we implemented the top-flop analysis in order to better improve the benchmarking implementation, identifying the best product on the market, basing on the highest number of innovative requirements owned by it, as shown by Frizziero in 2018 and Meuli et al. in 1997. The second part of the article focuses on the project of the kick scooter through the use of a software for the FEA simulation and on the possible realization of the prototype through a suitable connecting component.

Keywords: Benchmarking | Conceptual design | Innovation | Product design | QFD | Top-flop analysis | Transport | Vehicle

Abstract: The aim of this work is to complete the QFD analysis carried out in a previous work that aimed to identify the main features that contribute to the success of a modern urban transport means: the hoverboard. Starting from this analysis, through the TRIZ methodology, resolutive principles have been identified for the realization of innovative solutions of the said urban transport means. In practice this analysis aims to manage the next phase of conceptual design realized with the QFD methodology and tries to guide the design process in its next phase. In this work was used the hill model, a characteristic model of the TRIZ methodology, and the technical innovative problems encountered were reformulated in terms of technical contradictions. Subsequently, general principles of inventive solutions were obtained using one of the tools of TRIZ: the matrix of contradiction. Finally, starting from these general principles of solution, innovative constructive solutions have been developed to be applied to the design of an innovative hoverboard.

Keywords: contradictions | hill model | innovative solution | QFD | TRIZ | urban transportation systems

Abstract: Opening from an examination of all the best features of accomplishment of the hoverboard, a modern vehicle for urban transport, we have created inventive ideas to design the transport means itself. Quality Function Deployment methodology has given us the requirements to start from, while the TRIZ methods have provided us the proposals and notions of an innovative landscape to which we tend. In practice, while the QFD methodology has a powerfully conceptual appeal, and it is the basis of our analysis, the TRIZ method gives a more innovative thrust and deals the aspects that are strongly constructive and concrete. The Matrix of Contradictions was used within the Hill Model, and through it, we have been able to rework the innovative problems, suggested by the QFD analysis, in terms of technical contradictions. At the end of the work, a number of suggestions were made to further innovate this urban and modern means of transport: the hoverboard.

Keywords: Contradictions | Innovative solution | QFD | TRIZ | Urban transportation systems

Abstract: Sustainable design aims at the creation of physical objects, environment and services that complies to optimize social, economic, and ecological impact. QFD is able to assess the product design by the choice and definition of parameters that can be qualitatively discussed. The purpose of design is to meet a need in new ways and in innovative ways. In this context, the QFD aims at evaluating the quality of a design process. TRIZ is a design method that aim at defining and overcome some critical issue that can affect the development of a product, by means of potential innovative solutions. In this paper QDF and TRIZ analysis have been adopted in order to validate a design method for direct open moulds, by a new strategy: hybrid manufacturing can reduce the production time, the use of material, the energy and the waste consumption, employing subtractive and addictive techniques efficiently combined.

Keywords: Additive | Direct open mould | Hybrid manufacturing | QFD | Subtractive | TRIZ

Abstract: Sustainable design aims at the creation of physical objects, environment and services that complies to optimize social, economic, and ecological impact. QFD is able to assess the product design by the choice and definition of parameters that can be qualitatively discussed. The purpose of design is to meet a need in new ways and in innovative ways. In this context, the QFD aims at evaluating the quality of a design process. TRIZ is a design method that aim at defining and overcome some critical issue that can affect the development of a product, by means of potential innovative solutions. In this paper QDF and TRIZ analysis have been adopted in order to validate a design method for direct open moulds, by a new strategy: hybrid manufacturing can reduce the production time, the use of material, the energy and the waste consumption, employing subtractive and addictive techniques efficiently combined.

Keywords: Additive | Direct open mould | Hybrid manufacturing | QFD | Subtractive | TRIZ

Abstract: In high altitude operations, the cooling system takes part to the vehicle design optimization process. An integrated design of the cooling ducts is strictly necessary. At high altitudes, the cooling air is taken from high-pressure areas into an alternate, extremely optimized, path. A diffuser reduces the airspeed and increases pressure of the cooling air. Then a group of high performance finned radiators rejects the heat from coolant, air charge and oil. The high altitude, after diffuser radiator performance is discussed in this paper. At first high performance Formula 1 radiators are introduced and discussed. Experimental data are also exposed and summarized. The pressure drop and heat rejection are expressed in function or Re and Pr numbers of cooling air. Then the radiator performance at high altitude is extrapolated from the ground test data. Finally a few suggestions on radiator and cooling ducts arrangement are introduced.

Keywords: Cooling | HALE | Meredith effect | Optimization | Radiators | UAV

Abstract: Low BSFC (Brake Specific Fuel Consumption) and flat-altitude-rating make piston engines ideal choice for subsonic flight at altitudes up to 20, 000m-65, 000ft. These propulsion systems are more complex than traditional applications that are normally limited to 5, 000-7, 000m (16, 000-23, 000ft). In fact, the air propulsion (propeller or fan), the air intake and the cooling system take part have huge volumes. Therefore, their design influences vehicle aerodynamics as a whole. The cooling system is an integral part of aircraft design. As assessed from WWII design heritage, the cooling duct can be a static subsonic ramjet: the Meredith cooling duct. At high altitudes, the Meredith duct air is taken from highpressure areas into an alternate, extremely optimized, path. This path should end with a nozzle in a low pressure, high turbulence area of the aerial vehicle. In subsonic ramjet cooling ducts, the "static compressor" or diffuser is the most critical part. In fact the maximum compression ratio is below 1.5. Its efficiency highly influences the total thrust and the cooling efficacy of the duct. The Meredith duct should be embedded in the fuselage or in the wing to avoid excessive external drag. Only the air intake is positioned outside. In propeller systems, the intake is positioned in the lower part of the aircraft at about 2/3 of the wing chord, where the pressure reaches its maximum. In propeller systems, the high altitude engine intake can be positioned at the end of diffuser to increase the engine boost. In this way the turbomachinery mass and volume is reduced and the power to mass ratio of the propulsion system is increased. In fan systems, higher pressure is present inside the fan duct. In this paper, the preliminary design of the cooling duct is introduced. However, a CFD/wind tunnel optimization is strictly necessary to achieve a fully effective system. In any case, the requirements of low weight, high reliability and long endurance HALE (High Altitude Long Endurance) UAVs (Unmanned Aerial Vehicle) requires further work on this specific subject.

Keywords: Cooling | Diffuser | HALE | Meredith effect | Optimization | UAV

Abstract: Low BSFC (Brake Specific Fuel Consumption) and flat-altitude-rating make piston engines ideal choice for altitudes up to 20,000m-65,000ft. These propulsion systems are more complex than traditional applications that are normally limited to 5,000-7,000m (16,000-23,000ft). In fact, the air propulsion (propeller or fan), the air intake, the fuel system, the turbocharging, the exhaust and the cooling system take part to the design optimization process. An integrated design is strictly necessary. At high altitudes, the intake air is taken from high-pressure areas into an alternate, extremely optimized, path. In propeller systems, a diffuser is usually positioned in the lower part of the aircraft. It converts kinetic energy into pressure. In fan systems, a little amount of "high pressure" air is taken from the high-pressure area of the fan. In lower power units, automotive-derived turbochargers can achieve the required pressure ratio. However, this option is limited by the maximum amount of volumetric flow rate. Moreover, automotive turbocharger housings have to be redesigned to use low-weight inconel alloys instead of heavier cast-iron. A complete redesign of the high pressure turbocharger (the unit closer to the engine manifold) can achieve pressure ratios from 8:1 to 10:1. This expensive process increases the power to mass ratio of the propulsion system. For higher power rating over about 200 kW axial compressorturbine assemblies derived from small turboshafts can be used as a turbocharging unit. In this case the burner is substituted by the piston engine. Especially for diesel engines, the advantage lies in the efficiency (BSFC). In fact, the maximum temperature reached in the diesel combustion chamber is about 4200K and the air flow is much lower than traditional turboshafts. Hybrid and turbocompound solutions are also possible. The exhaust and the intake of the piston engine have to be redesigned. However, the requirements of low weight, high reliability and long endurance HALE (High Altitude Long Endurance) UAVs (Unmanned Aerial Vehicle) requires further work on this specific subject.

Keywords: HALE | Optimization | Propulsion | Serial cascade arrangement | Turbochargers | UAV

Abstract: Diesel and spark-ignition piston engines are an ideal choice for long endurance, high altitude operations (10, 000m/33, 000ft) and extremely high altitude operations (20,000m-65,000ft). These systems are more complex than traditional applications that are normally limited to 5, 000-7, 000m (16, 000-23, 000ft). In fact, the air propulsion system (propeller or fan), the air intake, the fuel system, the turbo charging, the exhaust and the cooling system take part to the design optimization process. An integrated design is strictly necessary. Since prop-fan is currently under development, the design should start from the choice between propeller and fan. This choice will influence optimum cruise speed, critical altitude and aircraft design as a whole. The air induction system is extremely important to improve efficiency, endurance and critical altitude. At low altitude, a filtered induction system is used for takeoff. At high altitudes, the intake air is taken from high-pressure areas into an alternate, extremely optimized, path. This induction system recovers as much pressure as possible, air kinetic energy at cruise speed. In propeller systems, the intake is usually positioned in the lower part of the aircraft. On fan systems, a little amount of "high pressure" air is taken from the high-pressure area of the fan. The exhaust system is also critical with the choice between pressure recovery and thrust. Exhaust-pressure-recovery reduces backpressure and temperature at exhaust. However, the improvement in critical altitude is marginal. In more common, thrust driven exhaust systems, the exhaust energy is converted into speed and thrust. At the relatively high speed of high altitude cruise, also the cooling system adds a small amount of thrust through the Meredith's effect. The piston engine power plant design is then extremely critical. Many different components should find the correct position for maximum performance. The power-plants of WWII water-cooled fighters and bombers are good examples, even if their design cruise altitude is below 10, 000m (33, 000ft). Modern turbofan and turbojet air intakes are also of help. However, the requirements of low weight, high reliability and long endurance HALE (High Altitude Long Endurance) UAVs (Unmanned Aerial Vehicle) requires further work on this specific subject.

Keywords: Cooling | HALE | Meredith effect | Optimization | Thruster | UAV

Abstract: This paper demonstrates that the experience from Formula 1 and watercraft racing can be applied directly to assess and improve the aircraft/maritime conversion of automotive commercial engines. A direct comparison of the main parameters that characterizes modern CRDID (Common Rail Direct Injection Diesel) and Formula 1 racing engine demonstrates that the similarities are hidden inside the design criteria. In fact, CRDIDs should output high torque at low rpm (1000-3000rpm) while racing engine should have top torque at 9000-11000 rpm. This fact introduces much shorter strokes in racing engines that reduce inertia loads. Since pressures are higher for CRDIDs the combustion loads are similar. The techniques used to improve the TBO of Formula 1 spark ignition engine and racing watercraft diesel can then be directly applied to naval and aircraft engines where the low-cost requirements are not so stringent as in mass-produced automotive CRDIDs (millions of items). The same technology that prolongs the Formula 1 TBO from a single race to the whole season can then be successfully used in aircraft/naval CRDIDs. A quantitative assessment of the TBO increase is included in this paper for the various systems that compose a CRDID.

Keywords: Common rail | Friction | Load factor method | Piston engines | TBO | Wear

Abstract: This paper demonstrates that efficiency and torque output of the actual Formula 1 power units depends mostly on the turbocharger (TC) efficiency. Compressor and turbine off-design efficiency and turbine energy recovery capability should be maximized to maximize the torque to fuel ratio. Since larger TCs increase turbolag, a new layout for the intercooler is proposed in this paper. This solution reduces turbolag and make it possible to focus on the TC efficiency as a thermal machine. In fact, not only the TC design choices can radically alter the efficiency of the TC itself, but also influence the efficiency of the ICE and of the MGU (Motor Generator Units). Energy evaluation of the TC readily exploits the concept.

Keywords: Compressor | ERS | Formula 1 | Intercooler | Turbine | Turbocharger

Abstract: The goal of this study is the analysis of the design process of aircraft propellers which are coupled to a piston engine, aiming to find the best design approach. The first design step is the calculation of the initial geometry. This phase is particularly critical since it will affect the following optimization. Several theories for blade design have been proposed during the years. The most popular are the Larrabee's procedure and the Theodorsen's theory. The Larrabee theory is the most used in recent years, while the Theodorsen was most popular in the WWII era. This work focuses on the differences on the results of the two approaches for a general aviation propeller for light aircrafts. For this aerial vehicle category both the strength and efficiency should be considered, since the production technology cannot be as refined as for larger propellers. As it will be seen, the subsonic nature of these aerial vehicles makes it possible to use both initial design approaches. In a second phase, the evaluation of the effect of aerodynamics and centrifugal loads requires the union of the results that come from CFD (Computational Fluid Dynamics) and the ones come from the CSM (Computational Structural Mechanics), through the execution of several one way FSI (Fluid Structure Interaction) analyses. However the starting point proved to be critical for the final result. The Larrabee procedure proves to be ideal for high speed aircraft propellers manufactured with up-to-date materials and procedures. The "old" Theodorsen theory leads to a stronger blade that can be easily manufactured with wood or simplified technologies. The Theodorsen blade is superior for the centrifugal load bearing capacity. This geometry leads to lighter blades. The efficiency of the Larrabee blade seems to be superior. However, experience proved that the CFD analysis can be tricky and unreliable for efficiency evaluation. The pressures are better distributed along the Larrabee's blade with better results at high airspeed. Eventually two geometrically optimized blades have been designed, which have a deformed shape (at cruise conditions) similar to the best aerodynamic geometry and comparable technological characteristics. The Larrabee and Theodorsen designs lead to different optimized blades even after the FSI simulation, demonstrating that the optimization procedure is largely influenced by the initial propeller blade design.

Keywords: Aircraft propeller | CFD | FEA | FSI | Optimization | Starting design

Abstract: In order to optimize the design of the thermodynamic cycle of a turbine (Brayton cycle) for using modern common rail as an “active” combustion chamber, it was intended to write the present paper. About the present case, the “active” combustion chamber produces a large amount of the mechanical energy that drives the fan. The incoming air is compressed by the compressor, then it is refrigerated and inputted in the diesel engine. A high pressure common rail system optimizes the combustion in the diesel combustion chamber and the expansion begins inside the diesel engine. At the exhaust of the combustion chamber, a turbine completes the expansion of the hot gases. A nozzle accelerates the exhaust from the turbine to increase the overall thrust.

Keywords: Aircraft | Diesel engines

Abstract: The goal of this study is the analysis of the CFD/FSI simulation accuracy of complex shapes with standard CADembedded software packages. In a PLM (Product Lifecycle Management) system, the continuous improvement of CADembedded FSI (Fluid System Interaction) software packages has progressively reduced the necessity for highly specialized external partners. These simulation software packages are designed to keep pace with the unavoidable design development. To make FSI and CFD usable for mechanical designers and design engineers from other engineering disciplines, CFD software package have been largely automated. The specialist expertise required to operate traditional CFD software may be negligible However, the capabilities of CAD-embedded CFD to handle complex geometries and to simulate complex industrial turbulent flows with heat and mass transfer raise question of the accuracy on the results obtainable by a nonspecialized designer. In this paper, a paraglider wing from NASA TN D3442 was used as a case study. This wing was modelled inside commercial CAD software and then thoroughly analysed by using the simulation tools with their default settings. The accuracy of results was then evaluated.

Keywords: CFD | FEA | FSI | Paraglider wing

Abstract: Back to the 1997 when this activity began, it was generally though that CRDIDs (Common Rail Direct Injection Diesel) would have completely replaced the piston gasoline engines used in aircrafts within a decade. This fact did not happen for several reasons. This paper tries to individuate these reasons. The more updated solutions to the many problems that almost stopped this application are also introduced. In this third part, maintenance and cost effectiveness related issues are introduced. Automotive OBD concept is described as a method to reduce maintenance costs and risks.

Keywords: Automotive and aerial-vehicle | Common rail direct injection diesel | On board diagnostic (OBD)

Abstract: Electric turbocompounding in racing spark ignition engine is focused on transient operation. Classical compressor and turbine maps should be adapted for this particular condition. Electric turbocompounding has limited torque and power available on the electric side. For this reason, an ad hoc solution should be devised. A low inertia solution is proposed in this paper with the advantage of minor modifications on existing commercial highly optimized turbochargers. A large advantage over the current solution may be achieved. In this solution, a very low inertia electric/motor generator is magnetically coupled to the turbocharger on the compressor side of the shaft. The electromagnetic coupling acts also as a torque limiter allowing extremely large slips between turbocharger and generator shafts.

Keywords: Electric turbocompound | Spark ignition engines

Abstract: Piston engines with power up to 1000HP (735.5 kW) are becoming popular in the aeronautical field for the high efficiency and the possibility to work with Diesel, jp4 and jp8 fuels up to altitudes up to 20,000m (65,000 ft). This paper updates a secondary advantage of piston engines: the Meredith effect. The Meredith duct is a ramjet powered by the heat wasted in cooling. In this way the efficiency of the original piston engine that can be higher than 50% which is the normal in common rail diesel engines. Even if the efficiency of this ramjet is lower than 30%, an accurate Design of this secondary engine can add a significant amount of thrust to the fan or the propeller powered by the piston engine. This effect, well known since the beginning of WWII, is being thoroughly analysed in this paper with regard of the efficiency. Previous papers introduced and a new radiator, with wing section tubes. As it will be seen the main design variable for the Meredith ramjet it the air temperature increase. This paper demonstrates that it is not convenient to increase this temperature over 200°C for aircrafts flying at about 600km/h@6000m (~330knots@20,000ft). The in-wing duct appears to be slightly better than the in-fuselage or the in-nacelle ones.

Keywords: Piston engine cooling

Abstract: Back to the 1997 when this activity began, it was generally thought that CRDIDs (Common Rail Direct Injection Diesel) would have completely replaced the piston gasoline engines used in aircrafts within a decade. This fact did not happen for several reasons. This paper tries to individuate these reasons. The more updated solutions to the many problems that almost stopped this application are also introduced. In this second part of this paper engine selection concepts and TBO (Time between Overhaul) are introduced.

Keywords: Avionization | Conversion | Diesel common rail

Abstract: Back to the 1997 when this activity began, it was generally thought that CRDIDs would have completely replaced the piston gasoline engines used in aircrafts within a decade. This fact did not happen for several reasons. This paper tries to individuate these reasons. The more updated solutions to the many problems that almost stopped this application are also introduced. In this first part FADEC related issues are introduced. Torsional vibration control is also briefly discussed.

Keywords: Aeronautical engines | Conversion of automotive engines | Diesel engines

Abstract: The marine propulsion system is the heart of the ship. Its reliability will directly affect the safe navigation and operating costs of ship and its overall safety. The individuation of the best propulsive solution is one of the key technologies in marine field. Focusing on the study of comprehensive reliability, this study analyses operation environments of the marine propulsion system firstly, and then evaluate the comprehensive reliability of the chosen marine propulsion system. According to the fault tree of the marine propulsion system, a CRDID (Common Rail Direct Injection Diesel) electric hybrid marine engine system is taken as an example The result shows that a new engine CRDID-hybrid system can be reliably installed on small boats and yachts. It is believed that the knowledge gained in this study will provide a theoretical reference for research on comprehensive reliability of hybrid marine propulsion systems.

Keywords: Diesel electric marine propulsion system | Failure probability | Fault tree analysis | Reliability

Abstract: Common rail automotive (Direct Injection) Diesels (DID) are always turbocharged. This engine works at limited altitude and should output torque at low rotational speeds. Not so for engines that work coupled to propeller and fans. This is the case of aircraft and helicopter engines. In this case it is important to have high output power at high rpm and to keep throttle authority and power at the higher altitude possible. Some basic concepts to achieve this result are introduced in this paper. Single turbocharging systems are introduced and an option to improve the altitude performance is discussed. Far from being exhaustive, this paper is an initial step in the long and awkward technology of turbocharging automotivederived engines. The basic concepts for efficiency are also discussed.

Keywords: Common rail automotive Diesels (DID) | Turbocharging

Abstract: In order to optimize the design of the thermodynamic cycle of a turbine (Brayton cycle) for using modern common rail as an "active" combustion chamber it was intended to write the present paper. About the present case, the "active" combustion chamber produces a large amount of the mechanical energy that drives the fan. The incoming air is compressed by the compressor, then it is refrigerated and inputted in the diesel engine. A high pressure common rail system optimizes the combustion in the diesel combustion chamber and the expansion begins inside the diesel engine. At the exhaust of the combustion chamber a turbine completes the expansion of the hot gases. A nozzle accelerates the exhaust from the turbine to increase the overall thrust. The mechanical energy from the diesel and from the turbine powers the compressor and the fan. The system can be seen as a turbocharged diesel engine with the turbocharger that outputs energy to the turbofan, increasing the output power and or the efficiency. A diesel-turbine compound can be realized in this way. The coupling of the two systems may be obtained in several different ways. The simplest is to put on the same shaft the compressor, the diesel crankshaft and the turbine. In front of the compressor a speed reducer drives the fan. A second example is to connect the turbine and the diesel on to electric generators. Electric engines are connected to the compressor and to the fan. The traditional turbodiesel has the compressor coupled to the turbine, and the diesel engine that moves the fan. In this latter case, however, the turbine does not energize the fan. Many other hybrid and nonhybrid solutions are possible. The problem is to optimize temperatures, pressures and rpm to the different machines that form the compound. The availability of many experimental data for diesel and turbines makes it possible to obtain a design of a "true" feasible optimum Diesel-Brayton cycle. This efficiency figure justifies the huge manufacturing and development costs of these turbocompound engines [1-4].

Keywords: Feasible optimum Diesel-Brayton cycle

Abstract: In the activity of injection mapping optimization, a good degree of knowledge on how a common rail injection works is strictly necessary. This paper is aimed to summarize the basic knowledge about turbocharged Common Rail Direct-injection Diesel engines (CRDID). It is possible to use automotive CRDIDs on aircrafts and helicopter; however their use is very different for the original car installation. For this reason a complete rethinking of the engine and the way the engine control is performed is strictly necessary. For this reason the engine should be reprogrammed for the new application. To perform this activity it is strictly necessary to know how the original automotive application works. This paper is aimed to this objective, in order to point out the differences with the automotive installation and the new optimization functions. The combustion process of turbocharged CRDID, equipped with high pressure common-rail fuel injection systems, with different boost pressures, injection pressures, and fuel quantities are introduced. The influence of the injection and the swirl mode on the ignition delay and the flame propagation is analyzed. The sac hole nozzles with a variable number of holes and different injector types (electromagnetic/piezoelectric) are also briefly described. An experimental analysis of the combustion process is briefly discussed along with spray penetration, dispersing angle, velocity, the distribution/evaporation of the fuel droplets, ignition delay, ignition location, combustion progression. The applied swirl has not an influence on the spray penetration, but it is extremely important for the ignition and the combustion process. On the contrary the swirl itself is reduced by the injected amount of high pressured fuel. The droplet turbulence increases from the center of the combustion chamber of the spray radial rapidly decreases. The difference in the combustion of CRDIDs, traditional diesel engines and spark ignition engine is also briefly discussed. Finally the difference from automotive and aircraft and helicopter CRDIDs, from the combustion tuning point of view is discussed. Optimum combustion (and mapping) is also introduced as basic concepts.

Keywords: Aircraft | Turbocharged di-diesel-engines

Abstract: Accessibility has always been a problem in sport car. Very low car floors, small doors, almost horizontal seating position with upward cramped legs are the negation of comfort. In marketing clips long legged girls show their knickers for the joy of the potential buyer. In the old times there were rumors that the four seats, automatic transmission Ferrari was made for the Drake himself, who was "obliged" to own and drive a Ferrari. Yet the only place where people with impaired legs are identical to all the others is the car. However the sports cars are usually denied to people with problems of motion. The Ercolani's idea was to overcome these problems by several concurrent solutions. The idea proved to be nice, while the design approach from sketch to 3D-CAD proved to be a complete failure. The final project fulfils many of the requirements, but with a completely different style. This project proved the substantial unfeasibility of the outside-in approach in the automotive field.

Keywords: ASTURA II | Car design

Abstract: Composite structures such as CFRP offer significant weight reduction over the conventional aluminum alloys for aircraft. Weight reduction improves fuel efficiency of the aircraft by approximately 20% which results in cost savings and simultaneously reduces the operational environmental footprint. However, the new aluminum-lithium alloys offer significant improvements and are viable alternatives to CFRP. Aluminum lithium alloy 2195 with Friction Stir Welding is introduced as a successful alternative to CFRP primary structures. A "thick skin" monocoque design with integral stringers as crack stoppers is discussed. An old Macchi 205 WWII fighter plane has been redesigned both in CFRP and 2195-FSW for comparison. The final designs are comparable in weight, but 2195-FSW is more competitive based on mass production costs, reparability, and environmental impact. Macchi 205 airplane is used due to in-depth experience with the original aircraft geometry and loads. Knowledge gained here can be directly transferred to larger structures, from corporate jets to large transport category airplanes [1].

Keywords: 2195-FSW | Aircraft structures | Aluminum alloys | CFRP | Composite material

Abstract: This paper introduces a method to simplify a nonlinear problem in order to use linear finite element analysis. This approach improves calculation time by two orders of magnitude. It is then possible to optimize the geometry of the components even without supercomputers. In this paper the method is applied to a very critical component: the aluminium alloy piston of a modern common rail diesel engine. The method consists in the subdivision of the component, in this case the piston, in several volumes, that have approximately a constant temperature. These volumes are then assembled through congruence constraints. To each volume a proper material is then assigned. It is assumed that material behaviour depends on average temperature, load magnitude and load gradient. This assumption is valid since temperatures varies slowly when compared to pressure (load). In fact pressures propagate with the speed of sound. The method is validated by direct comparison with nonlinear simulation of the same component, the piston, taken as an example. In general, experimental tests have confirmed the cost-effectiveness of this approach [1-4].

Keywords: CAD | FEA | Geometry | Optimization | Simulation

Abstract: This paper introduces an improved Electronic Stability Program for cars that can deal with the sudden burst of a tyre. The Improved Electronic Stability Program (IESP) is based on a fuzzy logic algorithm. The IESP collects data from the same sensors of a standard ESP and acts on brakes/throttle with the same actuators. The IESP reads the driver steering angle and the dynamic condition of the car and selectively acts on throttle and brakes in order to put the car on the required direction even during a tyre burst.

Keywords: ABS | ESP | Fuzzy logic | Tyre road contact

Abstract: The standard bicycle has a well defined form: two same-size in-line wheels with a triangular-shaped frame and an almost vertical riding position. This bike model is the "safety bicycle" 1870's model. May be it is not the most efficient form and, for sure, not the latest developed. The improvement had not been so important. There was indeed a big jump in the late 80's/early 90's, some of which could be attributed both to an increase in time trials and, may be, also to the doping practices of the time. In any case, doping of some form or another has been going on since the beginning of the Tour de France. Time trials are crucial for average speed and it may be they are entirely responsible for the improvement. In any case many other significant advantages have been made on the man-machine. Training and nutrition have been improved through the years. © 2006-2014 Asian Research Publishing Network (ARPN).

Keywords: Bicycle system | Electric facilities | Transportation

Abstract: The traditional automotive design process that starts from the sketches and the 2D drawings has been superseded by the modern CAD modeling tools. The step through the clay model and the following digitalization problems can be superseded. It is now possible to construct the inside and to define the ergonomic boundaries of the vehicle in an inside out process. This approach greatly reduces the time to market of the final product by including all the parts and the components that comes from other projects or from outsourcing. However a 1:1 (true scale) physical mock up of the vehicle is, in most the cases, still necessary. In fact the evaluation of the real aesthetics of the new project should be made in a true 3D environment. The inside-out approach optimizes the standardization, the outsourcing, the multi powertrains and the unified "platform" concepts. © 2006-2014 Asian Research Publishing Network (ARPN).

Keywords: Automotive design | Methodology to design | Optimization