Journal ArticleDOI
Economics of additive manufacturing for end-usable metal parts
Eleonora Atzeni,Alessandro Salmi +1 more
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In this paper, a comparison between two different technologies for metal part fabrication, the traditional high-pressure die-casting and the direct metal laser sintering additive technique, is done with consideration of both the geometric possibilities of AM and the economic point of view.Abstract:
Additive manufacturing (AM) of metal parts combined with part redesign has a positive repercussion on cost saving. In fact, a remarkable cost reduction can be obtained if the component shape is modified to exploit AM potentialities. This paper deals with the evaluation of the production volume for which AM techniques result competitive with respect to conventional processes for the production of end-usable metal parts. For this purpose, a comparison between two different technologies for metal part fabrication, the traditional high-pressure die-casting and the direct metal laser sintering additive technique, is done with consideration of both the geometric possibilities of AM and the economic point of view. A design for additive manufacturing approach is adopted. Costs models of both processes are identified and then applied to an aeronautical component selected as case study. This research evidences that currently additive techniques can be economically convenient and competitive to traditional processes for small to medium batch production of metal parts.read more
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Journal ArticleDOI
Challenges and opportunities to integrate the oldest and newest manufacturing processes: metal casting and additive manufacturing
TL;DR: The current state, technological challenges, economic opportunities and future directions in the growing “indirect” hybrid manufacturing ecosystem, which integrates traditional metal casting with the production of tooling via additive manufacturing (AM) process including three-dimensional sand printing (3DSP) and printed wax patterns are investigated.
Journal ArticleDOI
The economics of additive manufacturing: Towards a general cost model including process failure
TL;DR: A new AM cost model is generally specified so it can represent the probability and expected cost effect of failure events for all existing AM technologies and is applied to the manufacture of pharmaceutical products (tablets) using the AM technology variant material jetting.
Proceedings ArticleDOI
Topology optimization for additive manufacturing with controllable support structure costs
TL;DR: In this paper, the authors present a topology optimization formulation that allows the designer to find trade-off solutions between design performance and support structure costs, considering both printing and removal costs.
Journal ArticleDOI
Additive manufacturing cost estimation for buy scenarios
TL;DR: In this paper, the authors proposed a cost estimation model for laser sintering and laser melting based on analogical cost estimation techniques to estimate AM part cost based on the few parameters available at this point in the product development process.
Journal ArticleDOI
Additive manufacturing impacts on a two-level supply chain
TL;DR: In this article, the authors present an analytic approach based on Joint Economic Lot Sizing model, and aim at capturing the most significant impacts resulting from the implementation of the additive manufacturing concept on a two-level supply chain.
References
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Book
Additive Manufacturing Technologies: Rapid Prototyping to Direct Digital Manufacturing
TL;DR: Gibson et al. as discussed by the authors presented a comprehensive overview of additive manufacturing technologies plus descriptions of support technologies like software systems and post-processing approaches, and provided systematic solutions for process selection and design for AM Additive Manufacturing Technologies: Rapid Prototyping to Direct Digital Manufacturing.
BookDOI
Rapid manufacturing : an industrial revolution for the digital age
TL;DR: In this paper, the authors present a discussion of the potential of rapid manufacturing in the automotive industry and present a case study of how to modify a garden fork handle in order to make it more efficient.
Journal ArticleDOI
Rapid Manufacturing of Metal Components by Laser Forming
TL;DR: In this article, the main driving force of rapid prototyping or layer manufacturing techniques changed from fabrication of prototypes to rapid tooling (RT) and rapid manufacturing (RM), and nowadays, the direct fabrication of functional or structural end-use products made by layer manufacturing methods, i.e. RM, is the main trend.
Book ChapterDOI
Design for Additive Manufacturing
TL;DR: In this article, the capabilities of additive manufacturing technologies provide an opportunity to rethink DFM to take advantage of the unique capabilities of these technologies, and several companies are now using AM technologies for production manufacturing.
Journal ArticleDOI
Cost estimation for rapid manufacturing - laser sintering production for low to medium volumes:
TL;DR: In this article, a cost model for laser sintering is proposed, which leads to graph profiles that are typical for layer-by-layer manufacturing processes, and the evolution of cost models and the indirect cost significance in modern costing representation is shown.