Design of and with solution principles for additive manufacturing

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With additive manufacturing technologies new opportunities for product development arise due to the significant degree of design freedom. On the other hand, the technologies are subject to several limitations concerning the manufacturing accuracy, the maximum component size and the lot sizes. Therefore, for the development of competitive end products, which can be manufactured additively, an adjusted design-approach and changed solution principles are necessary.Solution principles for additively manufactured parts are characterized e.g. by an optimization of their functionality, a lightweight design, a limitation to available materials, production costs reduction and the consideration of the achievable accuracy. Solution principles which are designed for additive manufacturing (DfAM) stick to these boundaries.For this particular research project, a distinction is made between two separate elements of a DfAM. The design of solution principles for additively manufactured parts and the design with solution principles for additively manufactured parts are investigated. In the investigation on the design of DfAM-solution principles a method is created, which enables designers to develop solution principles for simple functions. For the creation of the method, solution principles designed for AM are collected and examined. The collection is expanded by adjusted and within the project developed solution principles.In the investigation on the design with solution principles for additively manufactured parts, a method is created to select single solution principles for the use in a specific product and adapt them to this purpose. For the design with solution principles for additively manufactured parts, the collection of solution principles created before can be used.The aim of the research project is to gain knowledge about elementary properties of AM-compliant solution principles and the function-integrating design with them. The focus is on the methodical approach to the development of solution principles and the development with solution principles under the aspect of the collection of standardized solution principles. The development of a methodical approach is to support the finding of AM-compliant component shapes for the realization of functions by means of additively manufactured components and thus to produce appropriate designs with a high degree of functional integration and a compact design. Furthermore, the methodical support should make the development of additively manufactured components more efficient.