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1. Graph Partitioning Technique to Identify Physically Integrated Design Concepts

   https://doi.org/10.1115/DETC2018-85646  

   Gopalakrishnan, Praveen Kumare; Kain, Helen; Jahanbekam, Sogol; Behdad, Sara (August 2018, 23rd Design for Manufacturing and the Life Cycle Conference)

   This study proposes a graph partitioning method to facilitate the idea of physical integration proposed in Axiomatic Design. According to the physical integration concept, the design features should be integrated into a single physical part or a few parts with the aim of reducing the information content, given that the independence of functional requirements is still satisfied. However, no specific method is suggested in the literature for determining the optimal degree of physical integration of a design artifact. This is particularly important with the current advancement in Additive Manufacturing technologies. Since additive manufacturing allows physical elements to be integrated, new methods are needed to help designers evaluate the impact of the physical integration on the design success. The objective of this paper is to develop a framework for determining the best way that functional requirements can be assigned to different parts of a product. 

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2. A Graph Partitioning Technique to Optimize the Physical Integration of Functional Requirements for Axiomatic Design

   https://doi.org/10.1115/1.4052702  

   Green, Emilyn; Estrada, Spenser; Gopalakrishnan, Praveen Kumare; Jahanbekam, Sogol; Behdad, Sara (May 2022, Journal of Mechanical Design)

   Abstract According to the concept of physical integration as understood in axiomatic design, design parameters of a product should be integrated into a single physical part or a few parts with the aim of reducing the information content, while still satisfying the independence of functional requirement. However, no specific method is suggested in the literature for determining the optimal degree of physical integration in a given design. This is particularly important with the current advancement in technologies such as additive manufacturing. As new manufacturing technologies allow physical elements to be integrated in new ways, new methods are needed to help designers optimize physical integration given the specific constraints and conflicts of each design. This study proposes an algorithm that uses graph partitioning to allow a designer to optimize the integration of functional requirements into a target number of parts, with the goal of minimizing the co-allocation of incompatible functional requirements in the same part. The operation and viability of the algorithm are demonstrated via two numerical examples and a practical example of designing a pencil. 

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3. Hybrid metal additive/subtractive machine tools and applications

   https://doi.org/10.1016/j.cirp.2024.05.002  

   Smith, Scott; Schmitz, Tony; Feldhausen, Thomas; Sealy, Michael (January 2024, CIRP Annals)

   Additive manufacturing creates parts by depositing a preform, typically layer by layer. Subtractive manufacturing involves removing material from a preform to create parts. Hybrid machine tools combine both additive and subtractive processes in the same workspace. They can be used to create parts that meet functional tolerance and surface finish requirements, or to create features that are difficult to produce using additive or subtractive processes alone. This paper describes hybrid metal additive/subtractive machine tools. It covers design considerations, sensors and controls, process management, programming and software, and the impact on the design space. It also identifies future research challenges. 

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4. Challenges and Opportunities for Integrating Dealloying Methods into Additive Manufacturing

   https://doi.org/10.3390/ma13173706  

   Chuang, A.; Erlebacher, J. (September 2020, Materials)

   null (Ed.)

   The physical architecture of materials plays an integral role in determining material properties and functionality. While many processing techniques now exist for fabricating parts of any shape or size, a couple of techniques have emerged as facile and effective methods for creating unique structures: dealloying and additive manufacturing. This review discusses progress and challenges in the integration of dealloying techniques with the additive manufacturing (AM) platform to take advantage of the material processing capabilities established by each field. These methods are uniquely complementary: not only can we use AM to make nanoporous metals of complex, customized shapes—for instance, with applications in biomedical implants and microfluidics—but dealloying can occur simultaneously during AM to produce unique composite materials with nanoscale features of two interpenetrating phases. We discuss the experimental challenges of implementing these processing methods and how future efforts could be directed to address these difficulties. Our premise is that combining these synergistic techniques offers both new avenues for creating 3D functional materials and new functional materials that cannot be synthesized any other way. Dealloying and AM will continue to grow both independently and together as the materials community realizes the potential of this compelling combination. 

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5. Studying Changes to the Additive Manufacturability of Design Solutions When Prepared and Simulated in Immersive Virtual Reality

   https://doi.org/10.1115/DETC2024-143204  

   Mathur, Jayant; Miller, Scarlett R; Simpson, Timothy W; Meisel, Nicholas A (August 2024, American Society of Mechanical Engineers)

   Abstract Solving problems with additive manufacturing (AM) often means fabricating geometrically complex designs, layer-by-layer, along one or multiple directions. Designers navigate this 3D spatial complexity to determine the best design and manufacturing solutions to produce functional parts, manufacturable by AM. However, to assess the manufacturability of their solutions, designers need modalities that naturally visualize AM processes and the designs enabled by them. Creating physical parts offers such visualization but becomes expensive and time-consuming over multiple design iterations. While non-immersive simulations can alleviate this cost of physical visualization, adding digital immersion further improves outcomes from the visualization experience. This research, therefore, studies how differences in immersion between computer-aided (CAx) and virtual reality (VR) environments affect: 1. determining the best solution for additively manufacturing a design and 2. the cognitive load experienced from completing the DfAM problem-solving experience. For the study, designers created a 3D manifold model and simulated manufacturing it in either CAx or VR. Analysis of the filtered data from the study shows that slicing and printing their designs in VR yields a significant change in the manufacturability outcomes of their design compared to CAx. No observable differences were found in the cognitive load experienced between the two modalities. This means that the experiences in VR may influence improvements to manufacturability outcomes without changes to the mental exertion experienced by the designers. This presents key implications for how designers are equipped to solve design problems with AM. 

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