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Design for Additive Manufacturing

Design for Additive Manufacturing
A Book

by Martin Leary

  • Publisher : Elsevier
  • Release : 2019-12-03
  • Pages : 358
  • ISBN : 0128168870
  • Language : En, Es, Fr & De
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Design for Additive Manufacturing is a complete guide to design tools for the manufacturing requirements of AM and how they can enable the optimization of process and product parameters for the reduction of manufacturing costs and effort. This timely synopsis of state-of-the-art design tools for AM brings the reader right up-to-date on the latest methods from both academia and industry. Tools for both metallic and polymeric AM technologies are presented and critically reviewed, along with their manufacturing attributes. Commercial applications of AM are also explained with case studies from a range of industries, thus demonstrating best-practice in AM design. Covers all the commonly used tools for designing for additive manufacturing, as well as descriptions of important emerging technologies Provides systematic methods for optimizing AM process selection for specific production requirement Addresses design tools for both metallic and polymeric AM technologies Includes commercially relevant case studies that showcase best-practice in AM design, including the biomedical, aerospace, defense and automotive sectors

Design for Additive Manufacturing

Design for Additive Manufacturing
Guidelines for Cost Effective Manufacturing

by Tom Page

  • Publisher : LAP Lambert Academic Publishing
  • Release : 2012-01
  • Pages : 46
  • ISBN : 9783847322948
  • Language : En, Es, Fr & De
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Additive Manufacturing is a new manufacturing method which adds material layer-by-layer to produce an object. This report set out to investigate a number of questions relating to Additive Manufacturing and its implications on current design practice, products and users. An introduction to Additive Manufacture as a process and how it has evolved from Rapid Prototyping is given. This report documents the Design for Manufacture constraints which Injection Moulding, a traditional manufacturing method, incurs and gives details of why most do not apply to Additive Manufacturing. The main freedom of traditional constraints comes from the nature of Additive Manufacturing being tool-less and therefore considerations such as constant wall thickness and non-undercutting geometry are not applicable. New constraints when 'Designing for Additive Manufacture' are given and explained including the need to remove support material or excess resin from within hollow geometry. Further still this report investigates consumer awareness and reception to Additive Manufacture through primary research in the form of a questionnaire - the first research of its kind into this topic.

Towards Design Automation for Additive Manufacturing

Towards Design Automation for Additive Manufacturing
A Multidisciplinary Optimization approach

by Anton Wiberg

  • Publisher : Linköping University Electronic Press
  • Release : 2019-10-14
  • Pages : 53
  • ISBN : 9179299857
  • Language : En, Es, Fr & De
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In recent decades, the development of computer-controlled manufacturing by adding materiallayer by layer, called Additive Manufacturing (AM), has developed at a rapid pace. The technologyadds possibilities to the manufacturing of geometries that are not possible, or at leastnot economically feasible, to manufacture by more conventional manufacturing methods. AMcomes with the idea that complexity is free, meaning that complex geometries are as expensiveto manufacture as simple geometries. This is partly true, but there remain several design rulesthat needs to be considered before manufacturing. The research field Design for Additive Manufacturing(DfAM) consists of research that aims to take advantage of the possibilities of AMwhile considering the limitations of the technique. Computer Aided technologies (CAx) is the name of the usage of methods and software thataim to support a digital product development process. CAx includes software and methodsfor design, the evaluation of designs, manufacturing support, and other things. The commongoal with all CAx disciplines is to achieve better products at a lower cost and with a shorterdevelopment time. The work presented in this thesis bridges DfAM with CAx with the aim of achieving designautomation for AM. The work reviews the current DfAM process and proposes a new integratedDfAM process that considers the functionality and manufacturing of components. Selectedparts of the proposed process are implemented in a case study in order to evaluate theproposed process. In addition, a tool that supports part of the design process is developed. The proposed design process implements Multidisciplinary Design Optimization (MDO) witha parametric CAD model that is evaluated from functional and manufacturing perspectives. Inthe implementation, a structural component is designed using the MDO framework, which includesComputer Aided Engineering (CAE) models for structural evaluation, the calculation ofweight, and how much support material that needs to be added during manufacturing. Thecomponent is optimized for the reduction of weight and minimization of support material,while the stress levels in the component are constrained. The developed tool uses methodsfor high level Parametric CAD modelling to simplify the creation of parametric CAD modelsbased on Topology Optimization (TO) results. The work concludes that the implementation of CAx technologies in the DfAM process enablesa more automated design process with less manual design iterations than traditional DfAM processes.It also discusses and presents directions for further research to achieve a fully automateddesign process for Additive Manufacturing.

A Practical Guide to Design for Additive Manufacturing

A Practical Guide to Design for Additive Manufacturing
A Book

by Olaf Diegel,Axel Nordin,Damien Motte

  • Publisher : Springer
  • Release : 2020-08-14
  • Pages : 226
  • ISBN : 9789811382833
  • Language : En, Es, Fr & De
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This book provides a wealth of practical guidance on how to design parts to gain the maximum benefit from what additive manufacturing (AM) can offer. It begins by describing the main AM technologies and their respective advantages and disadvantages. It then examines strategic considerations in the context of designing for additive manufacturing (DfAM), such as designing to avoid anisotropy, designing to minimize print time, and post-processing, before discussing the economics of AM. The following chapters dive deeper into computational tools for design analysis and the optimization of AM parts, part consolidation, and tooling applications. They are followed by an in-depth chapter on designing for polymer AM and applicable design guidelines, and a chapter on designing for metal AM and its corresponding design guidelines. These chapters also address health and safety, certification and quality aspects. A dedicated chapter covers the multiple post-processing methods for AM, offering the reader practical guidance on how to get their parts from the AM machine into a shape that is ready to use. The book’s final chapter outlines future applications of AM. The main benefit of the book is its highly practical approach: it provides directly applicable, “hands-on” information and insights to help readers adopt AM in their industry

Design for Additive Manufacturing

Design for Additive Manufacturing
Concepts and Considerations for the Aerospace Industry

by Dhruv Bhate

  • Publisher : Unknown Publisher
  • Release : 2019
  • Pages : 142
  • ISBN : 9781523124138
  • Language : En, Es, Fr & De
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A collection of ten seminal SAE International technical papers, which cover AM from the perspective of the appropriateness (should) and feasibility (can) of using AM for manufacturing of parts and tooling.

Design for Additive Manufacturing: FDM.

Design for Additive Manufacturing: FDM.
A Book

by Kacie Hultgren

  • Publisher : Unknown Publisher
  • Release : 2018
  • Pages : 329
  • ISBN : 9876543210XXX
  • Language : En, Es, Fr & De
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Designing for Additive Manufacturing

Designing for Additive Manufacturing
Perspectives from Product Design

by Steinar Killi

  • Publisher : Unknown Publisher
  • Release : 2013
  • Pages : 166
  • ISBN : 9876543210XXX
  • Language : En, Es, Fr & De
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Advanced Design for Additive Manufacturing: 3D Slicing and 2D Path Planning

Advanced Design for Additive Manufacturing: 3D Slicing and 2D Path Planning
A Book

by Donghong Ding

  • Publisher : Unknown Publisher
  • Release : 2016
  • Pages : 329
  • ISBN : 9876543210XXX
  • Language : En, Es, Fr & De
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Commercial 3D printers have been increasingly implemented in a variety of fields due to their quick production, simplicity of use, and cheap manufacturing. Software installed in these machines allows automatic production of components from computer-aided design (CAD) models with minimal human intervention. However, there are fewer options provided, with a limited range of materials, limited path patterns, and layer thicknesses. For fabricating metal functional parts, such as laser-based, electron beam-based, and arc-welding-based additive manufacturing (AM) machines, usually more careful process design requires in order to obtain components with the desired mechanical and material properties. Therefore, advanced design for additive manufacturing, particularly slicing and path planning, is necessary for AM experts. This chapter introduces recent achievements in slicing and path planning for AM process.

Additive Manufacturing

Additive Manufacturing
Design, Methods, and Processes

by Steinar Westhrin Killi

  • Publisher : CRC Press
  • Release : 2017-09-07
  • Pages : 240
  • ISBN : 1351767488
  • Language : En, Es, Fr & De
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Additive manufacturing has matured from rapid prototyping through the now popular and "maker"-oriented 3D printing, recently commercialized and marketed. The terms describing this technology have changed over time, from "rapid prototyping" to "rapid manufacturing" to "additive manufacturing," which reflects largely a focus on technology. This book discusses the uptake, use, and impact of the additive manufacturing and digital fabrication technology. It augments technical and business-oriented trends with those in product design and design studies. It includes a mix of disciplinary and transdisciplinary trends and is rich in case and design material. The chapters cover a range of design-centered views on additive manufacturing that are rarely addressed in the main conferences and publications, which are still mostly, and importantly, concerned with tools, technologies, and technical development. The chapters also reflect dialogues about transdisciplinarity and the inclusion of domains such as business and aesthetics, narrative, and technology critique. This is a great textbook for graduate students of design, engineering, computer science, marketing, and technology and also for those who are not students but are curious about and interested in what 3D printing really can be used for in the near future.

Additive Manufacturing Technologies

Additive Manufacturing Technologies
3D Printing, Rapid Prototyping, and Direct Digital Manufacturing

by Ian Gibson,David Rosen,Brent Stucker

  • Publisher : Springer
  • Release : 2014-11-26
  • Pages : 498
  • ISBN : 1493921134
  • Language : En, Es, Fr & De
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This book covers in detail the various aspects of joining materials to form parts. A conceptual overview of rapid prototyping and layered manufacturing is given, beginning with the fundamentals so that readers can get up to speed quickly. Unusual and emerging applications such as micro-scale manufacturing, medical applications, aerospace, and rapid manufacturing are also discussed. This book provides a comprehensive overview of rapid prototyping technologies as well as support technologies such as software systems, vacuum casting, investment casting, plating, infiltration and other systems. This book also: Reflects recent developments and trends and adheres to the ASTM, SI, and other standards Includes chapters on automotive technology, aerospace technology and low-cost AM technologies Provides a broad range of technical questions to ensure comprehensive understanding of the concepts covered

3D Printing Design

3D Printing Design
Additive Manufacturing and the Materials Revolution

by Francis Bitonti

  • Publisher : Bloomsbury Publishing
  • Release : 2019-07-11
  • Pages : 208
  • ISBN : 1350032190
  • Language : En, Es, Fr & De
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To work with the materials of tomorrow, design students across visual arts disciplines need to understand the cutting edge of today. Whether you're modelling in interiors, designing in fashion or constructing for interiors, in your work or as part of a final project, 3D Printing design is an encouraging guide to additive manufacturing within design disciplines. Francis Bitonti gives an insider's view from his design studio on how 3D printing is already shaking up the industry, and where it's likely to go next. Complete with interviews from designers, business owners and 3D-print experts throughout, Bitonti considers whether 3D body scans mean couture for all, how rapid prototyping can change your design method and if 3D printing materials can enhance medical design, amongst other areas of this emerging method of manufacture. This is inspirational reading for the designers of tomorrow.

Additive Manufacturing Technology - 3D Printing & Design - The 4th Industrial Revolution

Additive Manufacturing Technology - 3D Printing & Design - The 4th Industrial Revolution
3D Printing & Design

by Sabrie Soloman

  • Publisher : Unknown Publisher
  • Release : 2020-01-25
  • Pages : 418
  • ISBN : 9876543210XXX
  • Language : En, Es, Fr & De
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Additive Manufacturing Technology - The 3D Printing & DesignThe 4th Industrial Revolution - A 500 Page-Book of Innovation.Not ever previously consumer has had a technology where we so easily interpret the concepts into a touchable object with little concern to the machinery or talents available. 3D Printing Technology builds up parts by adding materials one layer at a time based on a computerized 3D solid model.It allows design optimization and the producing of customized parts on-demand. Its advantages over conventional manufacturing have captivated the imagination of the public, reflected in recent corporate implementations and in many academic publications that call additive manufacturing the "Fourth Industrial Revolution." 3D Printing produces 3D solid items from a digital computer file. The printing occurs in an additive process, where a solid object is generated through the consecutive layering of material. The process begins with the generation of a 3D digital file such as CAD file. The 3D digital file is then directed to a 3D Printer for printing using a simple print command.Freed of the constraints of traditional factories, additive manufacturing allows designers to produce parts that were previously considered far too complex to make economically. Engineers and Biologists are finding practical applications to use 3D additive manufacturing. It permits novel designs to become matchless rare-products that were not likely with preceding manufacturing methods. 3D Printing Technology is poised to transform medicine and biology with bio-manufacturing, and traditional manufacturing into 3D Printing. This technology has the possibility to upsurge the well-being of a nation's citizens. Additive manufacturing may progress the worldwide resources and energy effectiveness in "Ground, Sea and Air." This 3D Printing & Design book will enable you to develop and 3D Print your own unique object using myriads of available worldwide materials.One-off prototypes can be hideously expensive to produce, but a 3D Printer can bring down the cost by a sizable margin. Many consumers goods, mechanical parts, aerospace, automobiles, robots, shoes, fashions, architects' models, dentures, hearing aids, cell biology, now appear in a 3D-printed form for appraisal by engineers, stylists, biologist, and clients before obtaining the final approval.The 3D Printing Technology provides the additional advantage of removing many overhead manufacturing costs and time-delay. The rewards are substantial, as it permits product development teams effortlessly, rapidly and cost effectively yielding models, prototypes, and patterns to be manufactured in hours or days rather than weeks, or months.Digital Manufacturing3D printing - additive manufacturing, produces 3D solid items from a digital computer file. The printing occurs in an additive process, where a solid object is generated through the consecutive layering of material. There are an extensive variety of materials to select from countless lists of polymers and metals. The process begins with the generation of a 3D digital file such as CAD file. The 3D digital file is then directed to a 3D printer for printing using a simple print command.Freed of the constraints of traditional factories, additive manufacturing allows designers to produce parts that were previously considered far too complex to make economically. Engineers and Biologists are finding practical applications to use 3D additive manufacturing. It permits novel designs to become matchless rare-products that were not likely with preceding manufacturing methods. It is poised to transform medicine and biology with bio-manufacturing. This technology has the possibility to upsurge the well-being of a nation's citizens. Additive manufacturing may progress the worldwide resources and energy effectiveness in ground, sea and air.

Additive Manufacturing of Metals: The Technology, Materials, Design and Production

Additive Manufacturing of Metals: The Technology, Materials, Design and Production
A Book

by Li Yang,Keng Hsu,Brian Baughman,Donald Godfrey,Francisco Medina,Mamballykalathil Menon,Soeren Wiener

  • Publisher : Springer
  • Release : 2017-05-11
  • Pages : 168
  • ISBN : 3319551280
  • Language : En, Es, Fr & De
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This book offers a unique guide to the three-dimensional (3D) printing of metals. It covers various aspects of additive, subtractive, and joining processes used to form three-dimensional parts with applications ranging from prototyping to production. Examining a variety of manufacturing technologies and their ability to produce both prototypes and functional production-quality parts, the individual chapters address metal components and discuss some of the important research challenges associated with the use of these technologies. As well as exploring the latest technologies currently under development, the book features unique sections on electron beam melting technology, material lifting, and the importance this science has in the engineering context. Presenting unique real-life case studies from industry, this book is also the first to offer the perspective of engineers who work in the field of aerospace and transportation systems, and who design components and manufacturing networks. Written by the leading experts in this field at universities and in industry, it provides a comprehensive textbook for students and an invaluable guide for practitioners

Designing for Metal Additive Manufacturing

Designing for Metal Additive Manufacturing
Design Challenges with Three Industry Relevant Components

by Sai Nithin Reddy Kantareddy

  • Publisher : Unknown Publisher
  • Release : 2016
  • Pages : 329
  • ISBN : 9876543210XXX
  • Language : En, Es, Fr & De
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Additive manufacturing (AM) offers unprecedented design freedom to produce complex designs in a single step. Laser-based powder bed fusion, in particular, is a promising metal AM process to fabricate complex metal parts that are otherwise difficult, costly, or impossible to manufacture using traditional means. Many techniques for lightweighting designs and improving part performance such as topology optimization, lattice structures, and part consolidation, often result in designs with complex features that can only be made with AM. Although AM is not necessarily constrained by this geometric complexity, it does require unsupported/overhanging features in the design to be structurally supported by additional structures that can be later removed by post-processing using various techniques such as hand tools, machining, wire EDM (Electrical Discharge Machining), etc. Depending on the complexity of the part, support structures can often be substantial, difficult to access, and complex in shape; therefore, removing the support structures may be very difficult and require multiple post-processing steps. As a result, overall manufacturing cost, material consumption, and manufacturing time may unnecessarily increase, making AM less economical than initially conceived. Additionally, the thermo-mechanical nature of the metal AM process induces residual stresses and distortions in the built parts. In-process distortions can lead to build failures, part curling and warping, and material waste. Therefore, many designs cannot be easily manufactured using AM or may actually cost more to produce with AM. Design for Additive Manufacturing (DfAM) can remedy these limitations. DfAM encompass a set of principles or guidelines based on theory and experience to help design parts to be manufactured easily with AM. Effective implementation of DfAM during the design phase can result in parts suitable for AM, which can be affordable to make and easier to produce. However, the strategies to implement DfAM principles are not generalized and vary from part to part, process to process, and material to material. These part-specific requirements may require modifications in the existing design workflow, and a single workflow may not be suitable for all the design cases. To understand some of these differences, this thesis focuses on investigating the design process for leveraging metal AM capabilities at different levels of design complexities by redesigning three industry relevant components for additive manufacturing. In each case, the design conceptualization, workflow, design tools, DfAM principles, and improvement in product performance are compared and contrasted. Based on these three cases, recommendations are made for improving the design tools, and ultimately for improving the design workflow to reduce the computation time and improve the information flow across the software platforms.

Industrializing Additive Manufacturing

Industrializing Additive Manufacturing
Proceedings of AMPA2020

by Mirko Meboldt,Christoph Klahn

  • Publisher : Springer Nature
  • Release : 2020-09-01
  • Pages : 513
  • ISBN : 303054334X
  • Language : En, Es, Fr & De
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This book contains the proceedings of the Additive Manufacturing in Product Development Conference. The content focus on how to support real-world value chains by developing additive manufactured series products.

Additive Manufacturing Volume 2

Additive Manufacturing Volume 2
Alloy Design and Process Innovations

by Prashanth Konda Gokuldoss,Zhi Wang

  • Publisher : MDPI
  • Release : 2020-04-15
  • Pages : 352
  • ISBN : 3039284142
  • Language : En, Es, Fr & De
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Additive manufacturing (AM) is one of the manufacturing processes that warrants the attention of industrialists, researchers and scientists, because of its ability to produce materials with a complex shape without theoretical restrictions and with added functionalities. There are several advantages to employing additive manufacturing as the primary additive manufacturing process. However, there exist several challenges that need to be addressed systematically. A couple such issues are alloy design and process development. Traditionally alloys designed for conventional cast/powder metallurgical processes were fabricated using advanced AM processes. This is the wrong approach considering that the alloys should be coined based on the process characteristics and meta-stable nature of the process. Hence, we must focus on alloy design and development for AM that suits the AM processes. The AM processes, however, improve almost every day, either in terms of processing capabilities or processing conditions. Hence, the processing part warrants a section that is devoted to these advancements and innovations. Accordingly, the present Special Issue (book) focuses on two aspects of alloy development and process innovations. Here, 45 articles are presented covering different AM processes including selective laser melting, electron beam melting, laser cladding, direct metal laser sintering, ultrasonic consolidation, wire arc additive manufacturing, and hybrid manufacturing. I believe that this Special Issue bears is vital to the field of AM and will be a valuable addition.

Cost Modeling and Design Tools for Additive Manufacturing with Laser Powder Bed Fusion

Cost Modeling and Design Tools for Additive Manufacturing with Laser Powder Bed Fusion
A Book

by Michael W Barclift

  • Publisher : Unknown Publisher
  • Release : 2018
  • Pages : 329
  • ISBN : 9876543210XXX
  • Language : En, Es, Fr & De
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Additive Manufacturing (AM) is a novel process that uses 3D model data to create complex geometry and functional structures by joining materials layer-by-layer. Despite growing interest, industrys adoption of AM has been limited due to challenges in cost-effectiveness, lack of subject matter expertise, and disparities amongst commercial software programs that capture the full breadth of design inputs and process considerations for AM. Designers have limited tools within the 3D modeling (e.g., CAD) environment that inform them on critical design parameters and tradeoffs that can impact the overall cost and feasibility of producing a part in AM.In this thesis, cost modeling and design tools are examined for Laser-Powder Bed Fusion (LPBF). Traditional cost models have estimated that the material cost can range up to 46% of the total cost; however, these models have not accounted for the reuse (i.e., recycling) of the un-melted powder feedstock in LPBF. To capture susceptibilities to chemical contamination, diminished powder size distributions, and inconsistent mechanical performance, financial depreciation models using Sum-of-the-Years digits and Straight Line are implemented to define the value of a powder feedstock as function of each build cycle reuse in LPBF. A case-study is presented for an automotive upright designed for production and analyzed using a generic LPBF activity-based cost model. Sensitivity analysis revealed that traditional cost models assuming infinite material reuse undervalued the cost of build jobs with virgin powder by 3-11% or 13-75% depending on the material, feedstock price, and maximum permitted reuses in LPBF.Cost modeling is iterative and estimates will vary as updates are made to the 3D model. To aid in informing designers on costs of their parts, a software plug-in is presented using the SolidWorks Application Programming Interface (API) that integrates the proposed LPBF cost model within the 3D CAD environment. The tool enables designers to generate support structures and distinguish from internal and external supports on their part. In addition to querying volume and surface data from the 3D model, the manipulation of the parts build orientation allows designers to concurrently estimate build time, feedstock requirements, and optimize parts for AM production while they are being designed in CAD. A case study is presented for an automotive upright where results found that varying the support angle by 15 degrees, underpredicted support structure volume by 34% and build time by 20%. Furthermore, poor packing of geometries on the build platform led to powder depreciation costs being nearly twice the material costs. Based on this two-part study, recommendations are made for additional research on LPBF cost modeling, post-processing cost modeling, powder feedstock reusability metrics, and CAD-integrated design tools with greater inputs, support structure libraries, and considerations for AM processes.

Additive Manufacturing

Additive Manufacturing
The Potential to Revolutionise Sustainable Design

by Molly Byrne

  • Publisher : Unknown Publisher
  • Release : 2016
  • Pages : 68
  • ISBN : 9876543210XXX
  • Language : En, Es, Fr & De
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Industrializing Additive Manufacturing - Proceedings of Additive Manufacturing in Products and Applications - AMPA2017

Industrializing Additive Manufacturing - Proceedings of Additive Manufacturing in Products and Applications - AMPA2017
A Book

by Mirko Meboldt,Christoph Klahn

  • Publisher : Springer
  • Release : 2017-09-05
  • Pages : 362
  • ISBN : 3319668668
  • Language : En, Es, Fr & De
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These proceedings exchange ideas and knowledge among engineers, designers and managers on how to support real-world value chains by developing additive manufactured series products. The papers from the conference show a holistic, multidisciplinary view.

Advances in Additive Manufacturing, Modeling Systems and 3D Prototyping

Advances in Additive Manufacturing, Modeling Systems and 3D Prototyping
Proceedings of the AHFE 2019 International Conference on Additive Manufacturing, Modeling Systems and 3D Prototyping, July 24-28, 2019, Washington D.C., USA

by Massimo Di Nicolantonio,Emilio Rossi,Thomas Alexander

  • Publisher : Springer
  • Release : 2019-06-04
  • Pages : 671
  • ISBN : 303020216X
  • Language : En, Es, Fr & De
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This book discusses the latest advances in digital modeling systems (DMSs) and additive manufacturing (AM) technologies. It covers applications of networked technologies, ubiquitous computing, new materials and hybrid production systems, discussing how they are changing the processes of conception, modeling and production of products and systems of product. The book emphasizes ergonomic and sustainability issues, as well as timely topics such as DMSs and AM in Industry 4.0, DMSs and AM in developing countries, DMSs and AM in extreme environments, thus highlighting future trends and promising scenarios for further developing those technologies. Based on the AHFE 2019 International Conference on Additive Manufacturing, Modeling Systems and 3D Prototyping, held on July 24-28, 2019, in Washington D.C., USA, the book is intended as source of inspiration for researchers, engineers and stakeholders, and to foster interdisciplinary and international collaborations between them.