A new DFM approach to combine machining and additive manufacturing

TL;DR

This paper introduces a hybrid DFM approach that evaluates and optimizes the use of machining and additive manufacturing processes for different modules in product design, enhancing competitiveness.

Contribution

A novel DFM methodology that quantitatively assesses and integrates machining and additive manufacturing processes during product design.

Findings

Effective in guiding process selection for product modules.

Implemented in CAD software for industrial applications.

Validated on automotive industry products.

Abstract

Design For Manufacturing (DFM) approaches aim to integrate manufacturability aspects during the design stage. Most of DFM approaches usually consider only one manufacturing process, but products competitiveness may be improved by designing hybrid modular products, in which products are seen as 3-D puzzles with modules realized aside by the best manufacturing process and further gathered. A new DFM system is created in order to give quantitative information during the product design stage of which modules will benefit in being machined and which ones will advantageously be realized by an additive process (such as Selective Laser Sintering or laser deposition). A methodology for a manufacturability evaluation in case of a subtractive or an additive manufacturing process is developed and implemented in a CAD software. Tests are carried out on industrial products from automotive industry.