Design Methodology for Additive Manufacturing

186 Pages·2016·27.17 MB·English

Delft University of Technology

Design Methodology for Additive Manufacturing
Supporting Designers in the Exploitation of Additive Manufacturing Affordances
Doubrovski, Zjenja
DOI
10.4233/uuid:d4214bb0-5bfd-43fe-af42-01247762b661
Publication date
2016
Document Version
Final published version
Citation (APA)
Doubrovski, Z. (2016). Design Methodology for Additive Manufacturing: Supporting Designers in the
Exploitation of Additive Manufacturing Affordances. https://doi.org/10.4233/uuid:d4214bb0-5bfd-43fe-af42-
01247762b661
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Design Methodology for
Additive Manufacturing
E.L. Doubrovski
Design Methodology for Additive Manufacturing
Supporting Designers in the Exploitation of Additive Manufacturing Affordances

E.L. Doubrovski
Design Methodology for Additive Manufacturing
Supporting Designers in the Exploitation of Additive Manufacturing Affordances

ISBN: 978-90-6562-401-7
Published by: Delft Academic Press

Copyright © 2016 by E.L. Doubrovski. All rights reserved. No part of this publication may be
reproduced, stored in a retrieval system or transmitted in any form or by means, without prior
written permission of the author.
Design Methodology for Additive Manufacturing
Supporting Designers in the Exploitation of Additive Manufacturing Affordances

Proefschrift

ter verkrijging van de graad van doctor
aan de Technische Universiteit Delft,
op gezag van de Rector Magnificus prof.ir. K.C.A.M. Luyben;
voorzitter van het College voor Promoties,
in het openbaar te verdedigen op 8 december 2016 om 15:00 uur

door

Eugeni Leonidovitsch DOUBROVSKI

ingenieur Industrieel Ontwerpen,
Technische Universiteit Delft, Nederland
geboren te Moskou, Sovjet-Unie
This dissertation has been approved by the
promotors: Prof.dr.ir. J.M.P. Geraedts and Prof.dr. I. Horváth
copromotor: Dr.ir. J.C. Verlinden

Composition of the doctoral committee:
Rector Magnificus chairman
Prof.dr.ir. J.M.P. Geraedts Delft University of Technology
Prof.dr. I. Horváth Delft University of Technology
Dr.ir. J.C. Verlinden Delft University of Technology

Independent members:
Prof.ir. D.N. Nas Delft University of Technology
Prof.dr. M. van Hecke Leiden University
Dr. R.I. Campbell Loughborough University (United Kingdom)
Dr. N. Oxman Massachusetts Institute of Technology (USA)
Prof.dr. C.C.L. Wang Delft University of Technology, reserve member
Contents
1 Introduction 9
1.1 Traditional design and manufacturing 10
1.2 Introduction to Additive Manufacturing 13
1.3 Trends of digitalization 17
1.4 Brief history of Additive Manufacturing 22
1.5 Recent developments of AM in industry 23
1.6 Challenges for the AM industry 27
1.7 Hypothesis and research objective 29
1.8 Research approach 31
1.9 Thesis content 34
2 Research Cycle 1: Defining the focus 37
2.1 Introduction 37
2.2 Academic landscape of AM 37
2.3 Proposed approaches Design for Additive Manufacturing 42
2.4 Learning the limitations: Explorative experiments 52
2.5 Conclusions 58
3 Research Cycle 2: Learning from the AM application context 63
3.1 Introduction 63
3.2 Pioneers’ lessons 63
3.3 Design experiments 73
3.4 Observations from design experiments 83
3.5 Conclusions 84
3.6 Discussion 86
4 Research Cycle 3: Design methodology development 89
4.1 Objective 89
4.2 Approach 89
4.3 Underpinning theory 89
4.4 Formulating the DfAM framing methodology 95
4.5 Concluding remarks on methodology development 100
5 Research Cycle 4: Validation of DfAM methodology 103
5.1 Introduction 103
5.2 Validation method 103
5.3 Execution of validation by using the Validation Square 109
5.4 Conclusions 116
6 Conclusions 121
6.1 Contributions 121
6.2 Proposal for further research 124
6.3 Dissemination of the results of the conducted research through demonstrators 129
6.4 Reflection on the process 132
6.5 Implications of this research 132
References 137
Summary 153
Samenvatting 163
Publications by the author 175
Acknowledgements 177
About the author 179
Appendix A 183
Chapter 1
Introduction

Related publication
Doubrovski, E. L., Verlinden, J. C., & Geraedts, J. M. P. (2011). From Factory to Replicator: Towards Design
Methods for On-Demand Additive Manufacturing. In N. F. M. Roozenburg, L. L. Chen, & P. J. Stappers (Eds.),
Proceedings of IASDR 2011, 4th World Conference on Design Research. Delft, The Netherlands.
Drawing, designing, and building things have been personal interests
of mine for as long as I can remember. The advent of digital tools for
drawing and design sparked my interest for the digital domain, while
the making of things appeared to remain an analog skill. It was not
until 2000, reading an eye-opening article on 3D printing by Bolt
(2000), that I realized that the tools for making were now also entering
the digital world.
Although the first Additive Manufacturing (AM) technologies are
almost 30 years old, it was only in recent years that the application of
AM as a means of product manufacturing started to grow
significantly, impacting products and the daily life of companies,
designers, and consumers. When used as a manufacturing method,
what are the important novel aspects of AM? What changes could it
introduce to the discipline of design?
As a designer, these questions fascinated me. Doing the research
presented in this thesis proved to be a unique opportunity to be part of
an exciting new field.