Robust Design Principles to Evaluate Additive ...

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International Symposium on Robust Design (ISoRD'14) Technical University of Denmark, DTU

Robust Design Principles to Evaluate Additive Manufacturing Capabilities
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Author:Iñigo Flores (Department of Design and Production, Aalto University, Finland)
Eric Coatanea (Department of Design and Production, Aalto University, Finland)
Mika Salmi (Department of Design and Production, Aalto University, Finland)
Jukka Tuomi (Department of Design and Production, Aalto University, Finland)
Date: 2014-08-15     Track: Main     Session: 13:00-14:30 Oral Session 2 - Robustness in Production
DOI:10.4122/dtu:2101

Additive manufacturing (AM) is generating a paradigm shift by expanding the manufacturing capabilities. However, quality of AM produced parts is dependent on a number of machine, geometry and process parameters. The impact of inputs, such as the machine technology, the part orientation, the part location and the quality of the digital data, affects the AM outcomes drastically. A new user faces the problem of selecting optimal sets of input variables and therefore, it is necessary to support this selection process that is based typically in tacit knowledge of the machine operator or service suppliers. The present research has proposed a “composite” methodology integrating Taguchi design of experiments, multi-objective optimization and statistical process control, to optimize the manufacturing process and fulfil multiple requirements imposed to an arbitrary geometry. This study provides a comparative assessment of AM technologies and optimal process parameters. During the experiment, three conflicting requirements were imposed to a case geometry. Two of them, at the macro level, evaluated dimensional and geometrical tolerances. The third one, at the micro level, evaluated the surface quality of the produced parts. The outcomes of the experiment indicate that only one machine (M1, Stereolithography), was feasible to simultaneously fulfil macro and micro level requirements. In addition, the process was capable but not centred according to production standards. Future study including mechanical performance variables, interaction between variables and impact of noise factors is planned.