Abstract

This case study delves into the benefits of integrating 3D Spark, a tool for Design for Manufacturing (DfM) checks, technology and material selection, and production cost analysis, in an academic environment. By navigating through the various student-led projects at HAW University, we examine how 3D Spark serves as an educational aid, enriching students' comprehension of additive manufacturing (AM) processes, design optimization, and the crucial economic aspects of production.

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Introduction

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The evolution of additive manufacturing (AM) technologies presents new design and manufacturing challenges, necessitating innovative educational approaches. HAW Hamburg University of Applied Sciences is at the forefront of integrating advanced tools into its curriculum to meet these demands. Since 2020, Prof. Dr. Jens Telgkamp has offered a master module for students in product development, numerical simulation, and production technology. This module focuses on design rules for AM topology optimization, guiding students through the entire development process of an AM part—from the basic idea, concept, and detail design phases to simulation, certification, and economic assessment.

In 2023, 3D Spark, a tool for Design for Manufacturing (DfM) checks, technology and material selection, and production cost analysis, was introduced to this module. By incorporating 3D Spark into student projects, HAW Hamburg aims to equip future engineers with the skills necessary to leverage AM's full potential. The tool emphasizes hands-on learning in Design for Manufacturing checks, technology and material efficiency, and cost-effective production.

Students are offered a suite of software solutions such as Autodesk Fusion 360 / NetFabb, ALTAIR, nTop, Inspire / Optistruct, Synera, ANSYS, CREO, CATIA, and Siemens NX for design, topology optimization, FEA, and build preparation. Students are free to combine these solutions to complete their projects. The majority of the teams chose to combine 3D Spark with these design, topology optimization, FEA, and build preparation tools. During the design cycles, 3D Spark helped as a quick tool to evaluate Design for Manufacturing (DfM) and costs.

The practical applications of the 3D Spark platform can be seen in the following student-led case studies.

• Optimization of Brake Caliper for HAWKS Racing:
  •  Domain: Automotive / Racing‍
  • Objective: Enhance the performance of a racing vehicle by optimizing the brake caliper's design for reduced weight and improved thermal properties, while ensuring cost-effectiveness through additive manufacturing (AM).
  • Approach: The project utilized topology optimization techniques to redesign the brake caliper, focusing on material distribution to withstand high stress and thermal loads. Laser Powder Bed Fusion (LPBF) with Scalmalloy (AlSi10Mg) was chosen for its superior strength-to-weight ratio.‍
  • 3D Spark Application:  3D Spark provided insights into manufacturability and the economic feasibility of the new design and material used for the selected manufacturing technology, aiding in decision-making based on performance and cost-efficiency metrics.‍
  • Outcome: Achieved a 30.15% reduction in mass and a 43.3% reduction in maximum stress, demonstrating the potential of AM in producing high-performance automotive components at lower costs.

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• ‍Weight Reduction of Wheelchair Footrests through Topology Optimization and Additive Manufacturing:
  • Domain: Healthcare / Medical Devices‍
  • Objective: Improve the usability and energy efficiency of wheelchairs by reducing the weight of the footrests without sacrificing strength or user comfort.‍
  • Approach: The project applied topology optimization to redesign the footrest with minimal material use while maintaining functionality. The use of AM enabled the realization of complex geometries that were not possible with traditional manufacturing methods. Additive manufacturing techniques such as SLM, EBM, LENS, WAAM (Wire Arc Additive Manufacturing), and BJ were considered, with SLM selected for its ability to handle high complexity and provide good mechanical properties. Different materials were also compared to identify the best suited one for the new design and production technology.‍
  • 3D Spark Application:  3D Spark was pivotal in conducting Design for Manufacturing (DfM) assessments and pinpointing the optimal technology and material choice (AlSi10Mg) for the new footrest design. It offered a comprehensive evaluation of various iterations based on weight, strength, and cost, enhancing part development through fast-tracked manufacturability assurance and cost assessments. This capability empowered designers to methodically refine and juxtapose designs, ensuring the attainment of an ideal solution that merges concept with production-readiness efficiently.‍
  • Outcome: Despite an increase in price of approximately 158% due to the shift to additive manufacturing, the project presents a compelling case for the adoption of the innovative design by balancing increased upfront costs against the benefits of a reduction in weight of approximately 32% and potentially lower lifetime operating costs.

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• ‍Topology Optimization of a Tool Carrier for a Thermoforming Oven:
  • ‍Domain: Industrial / Manufacturing‍
  • Objective: Minimize the tool carrier's thermal capacity and weight to achieve energy savings and improved handling.‍
  • Approach: Utilized topology optimization to streamline the design for effective heat management and reduced material usage. AM was selected for its ability to produce complex, lightweight structures.‍
  • 3D Spark Application: Facilitated the exploration of additive manufacturing techniques suitable for the tool carrier design, offering a detailed energy consumption and cost-benefit analysis of the old and new tool carriers highlighting the advantages of AM in achieving energy efficiency and cost savings.‍
  • Outcome: The redesign resulted in improved thermal properties with a weight reduction of around 62.3%, highlighting AM's role in enhancing manufacturing processes.

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• Topology Optimization of a Heavy-Duty Castor for Automated Guided Vehicles:
  • Domain: Logistics / Automated Transportation
  • ‍Objective: Redesign a heavy-duty castor for improved performance in Automated Guided Vehicle (AGVs), focusing on durability and ease of manufacturing while keeping manufacturing costs in mind.‍
  • Approach: The castor was optimized for material efficiency and manufacturing simplicity using topology optimization. SLM technology was selected as the suited manufacturing technology for the optimized design, taking advantage of its flexibility in manufacturing complex shapes.‍
  • 3D Spark Application: Contributed to the selection of manufacturing processes, with a focus on assessing the feasibility and cost of producing the optimized castor using varied materials, guiding the selection towards the most cost-effective and robust solution.‍
  • Outcome: The optimization led to an 81% reduction in the weight of the caster. The detailed cost analysis revealed that producing the caster in AlSi10Mg would cost €5,638 compared to €12,334 for 316L, highlighting the substantial cost savings possible with the selected SLM process and material AlSi10Mg. These figures underscore the project’s success in demonstrating the practical benefits and economic viability of applying AM for industrial components in automated transportation.

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Application of 3D Spark:

• ‍DfM Checks and Manufacturability Assurance: 3D Spark facilitated rapid evaluation of design modifications, enabling students to understand and apply DfM principles effectively.‍
• Technology Selection: Technology Selection: The tool offered valuable insights into selecting the appropriate manufacturing technology by aligning part design with the capabilities of additive manufacturing to achieve the desired outcomes efficiently.‍
• Costing: 3D Spark's cost estimation features were instrumental in conducting economic analyses, offering students a clear perspective on AM's cost dynamics.‍
• Material Selection: Leveraging the software's comprehensive material database to find the optimal balance between performance, weight, and cost.

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Results

The integration of 3D Spark into these projects resulted in:

• ‍Enhanced student engagement and practical experience: Students gained hands-on experience with AM technologies, design principles, material selection, etc. by applying classroom theories to solve complex engineering problems.
• Innovative Solutions: Each project yielded innovative solutions that met or exceeded project objectives, demonstrating the potential of AM in various industries.
• Economic Viability: Projects achieved a balance between innovation and cost, displaying the practicality of AM in producing commercially viable products.

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 Testimonial

"Integrating 3D Spark into our curriculum has transformed the way our students engage with additive manufacturing. Through hands-on projects like optimizing brake calipers for racing vehicles, they not only grasp theoretical concepts but also develop practical skills crucial for their future careers. 3D Spark's comprehensive tools for design optimization and cost analysis have truly helped raise our educational efforts."

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Conclusion

3D Spark has proven to be an invaluable tool in additive manufacturing education, enriching student learning experiences through practical applications in design optimization, material selection, and cost analysis. By providing a hands-on approach to tackling AM challenges, 3D Spark not only enhances educational outcomes but also prepares students for future careers in engineering and manufacturing. The case studies underscore the importance of continuous software development and curriculum integration to fully exploit AM's transformative potential.