Design for Hybrid Manufacture - DHARMA

在新兴技术和方法方面，英国制造业正在经历重大转型和转型。传统的观点是在一个精确定义的逻辑步骤序列中使用一系列不同的工艺，现在正受到金属增材层技术的不断出现和发展的挑战，最通常被称为增材制造。随着该行业的预计增长（目前的年复合增长率为34.9%），它在制造业的持续参与将大大增加。然而，主要的瓶颈是组件初始生成后所需的大量额外精加工过程。增材制造和减法工艺的流线型和集成组合现在被称为混合制造。当前的制造方法设计是成熟的技术，允许设计适应使用传统的线性制造方法进行高效生产。然而，如果没有重大的修改和适应，这些目前最先进的方法并不能直接适用于新兴的制造技术。这将阻碍新的和新兴的制造工艺的产生和吸收，进一步停滞设计。DHarMa项目（混合制造设计）旨在提供一种颠覆性的设计原理和工艺，专门针对混合制造（HM）形式的组合增材和减材技术的增强利用。这将通过进行系统的、定量的和定性的研究来实现，这些研究将重点放在生成混合制造过程的设计上，基于已确定的设计特征和几何分类，与混合制造关键性能指数和制造能力框架无缝结合。达摩将结合具体的加法和减法制造信息结构，结合设计特征和几何关系和属性。从本质上讲，这将集成和分类零件特定的设计和制造信息，并将用于生成DHarMa过程。设计师将有一个强大的工具，使他们能够定制和调整他们的设计，以使用加法和减法技术的组合制造。与传统制造在可以正确生成的特征和几何形状方面具有重大限制不同，增材制造具有直接创建高度复杂特征和几何形状的能力，这些特征和几何形状通常是使用传统方法无法实现的（例如，非物质化的内部薄壁特征）。这为设计师提供了更多的设计自由和灵活性，从而使他们能够创造新的创新产品，而不需要受到一套严格的传统制造协议的限制。该可行性项目将为设计过程的生成提供初步研究，该设计过程将使零件能够使用HM方法进行专门设计。这将首先基于将应用于HM的棱柱设计。

Manufacturing in the UK is undergoing significant transitions and transformations in terms of new emerging technologies and methods. The traditional view of using a range of disparate processes in a precisely defined logical sequence of steps is now being challenged by the continued emergence and growth of metal additive layer technologies, most commonly termed additive manufacturing. With projected growth in this sector increasing (current annual compound growth rate is 34.9%), it's continued involvement in manufacturing is set to increase considerably. However, the major bottleneck is the significant additional finishing processes required after initial generation of the component. The streamlined and integrated combination of AM and subtractive process is now being termed hybrid manufacture. Current design for manufacture methods are well-established techniques that allow designs to be adapted to enable efficient production using traditional linear manufacturing approaches. However these current state of the art methods are not directly applicable to new emerging manufacturing techniques, without significant modification and adaption. This will impede the generation and uptake of novel and emerging manufacturing processes, further stagnating design. Project DHarMa (Design for Hybrid Manufacture) aims to deliver a disruptive, design rationale and process that is specifically targeted at enhanced utilisation of combined additive and subtractive technologies in the form of hybrid manufacture (HM). This will be achieved by undertaking systematic, quantitative and qualitative research that will focus on generating a design for hybrid manufacturing process, based on identified design features and geometry classifications in seamless conjunction with hybrid manufacturing key performance indices and a manufacturing capability framework. DHarMa will incorporate specific additive and subtractive manufacturing information constructs in conjunction with design feature and geometry relationships and attributes. Essentially this will integrate and categorise part specific design and manufacturing information and will be used to generate the DHarMa process.Designers will have a powerful tool that will enable them to tailor and adapt their designs to be manufactured using a combination of additive and subtractive technologies. Unlike conventional manufacturing that has significant limitations in terms of features and geometries that can be correctly generated, AM un-constrains manufacturing with the direct capability to create highly complex features and geometries that would be typically inaccessible using conventional methods (for example, dematerialised internal thin walled features). This affords the designer more design freedom and flexibility, thus empowering them to create new innovative products without the need to be constrained by a rigid set of conventional manufacturing protocols. This feasibility project will provide the initial study in to the generation of a design process that will enable parts to be specifically designed for manufacture using a HM approach. This will initially be based on prismatic designs that will be applied to HM.