KREATIVE – Design methodology for the hybrid additive manufacturing

The research project KREATIVE is concerned with the development of an advanced design methodology for the production of components using the hybrid additive manufacturing. The project aims to develop a comprehensive manual that provides clear guidelines for designing components that should be fabricated using a combination of manufacturing processes. The focus is on aspects such as the manufacturability, the cost efficiency, an improved functionality, and the resource efficiency.

Initial situation

The need for customized and weight-optimized designs is growing in an increasingly individualized and environmentally conscious world. In parallel, the reduction of the overall resource consumption in the manufacturing industry is becoming increasingly necessary to ensure both environmental and economic benefits. The combination of different manufacturing processes offers great potentials in terms of the efficiency and the product functionality to meet these requirements. Especially in the fabrication of complex components, combining different manufacturing processes can play a key role in the future production landscape.

Objective and expected results

The research project KREATIVE focuses on building a design methodology for the hybrid additive manufacturing. Hybrid additive manufacturing refers to a combination of different additive manufacturing processes, but also to the combination of an additive with an established and cost-effective conventional manufacturing method. The main goal is to provide end users with guidelines for the design of industrial components. Among others, the manufacturability, the cost efficiency, an improved functionality, and the resource efficiency are considered. Topology optimization and process simulation methods will improve the component design and anticipate potential problems during the manufacturing process. The documentation of the project results within a systematic design methodology, which will provide industry users with a practical guide to assist in the design of components manufactured by the hybrid additive manufacturing.

Approach

The project starts with the derivation of a systematic approach for the suitability evaluation of industrial components for the hybrid additive manufacturing and a detailed investigation of the joint region. Then, the design areas and interfaces of the components are clearly defined, followed by the detailed planning of a hybrid process chain. The design process is performed through an innovative automated method using the topology optimization. The manufacturability and the effect of process parameter adjustments are simulated in an iterative exchange with the designer to extend the process limits. Once the manufacturability has been validated through the successful fabrication of demonstrator components, the work culminates in the creation of a systematic design methodology. This guide is finally subjected to the industrial validation at one of the partner companies.

Acknowledgements

The research project KREATIVE is funded by the German Federal Ministry for Economic Affairs and Climate Action (number 03LB1015C) and supervised by the Project Management Jülich. We would like to thank the project partners for their excellent support and cooperation.