Design for additive manufacturing using triz-am principles in supporting product design and development

Abstract

Design for additive manufacturing (DFAM) can be categorized into design and manufacturing decisions to support designers in utilizing additive manufacturing (AM) capabilities such as design freedom and complex geometry. The idea of DFAM is similar to the goals of TRIZ (Theory of inventive problem solving), where it provides tools for innovative and creative solutions to address design problems during product design and development (PDD). Past researches in connecting TRIZ and AM indicated that it can be realistically used in assisting DFAM. However, it was found that the existing 40-innovative principles (40IPs) of TRIZ could not solely provide inclusive solutions to be applied to all AM technologies and terminologies. Moreover, the usage of TRIZ 40IPs in AM is highly dependent on the available AM examples which are subjective to researchers’ problem-solving viewpoints and does not cover new innovative principles represented by AM design knowledge. Therefore, this study aimed to develop a DFAM procedure integrated with TRIZ-AM by enhancing the definition of classical TRIZ inventive principles according to AM applicability and suitable AM scenario. The 40 IPs were revised according to the classifications of design heuristics, principles, and guidelines applicable to AM. TRIZ-AM cards were developed to assist designers with infographic design knowledge. In addition, a manufacturability analysis of AM-printed parts was performed for the material extrusion process using composite materials. Experimental work was conducted using carbon fiber- polylactide acid (PLA) and Wood-PLA filaments involving seven types of basic structures, and four types of lattice structures. All of the printed parts were then inspected, measured, and compared with Virgin PLA. The outcomes were based on the data obtain from computer aided design (CAD) and printed part with regard to the development of design rules. To demonstrate its applicability, a new mobile application for composite design rules (CDRs) applications was developed. Fourteen outcomes of case studies were produced, including the design modification and improvement of consumer products. Designers from various industrial backgrounds were involved to perform the design task according to the specific DFAM requirements. Resultantly, the dimensional accuracy of basic structures produced was approximately 80% to 90% closer to CAD data when compared with Virgin PLA. The strut lattice size of more than 2.00 mm produced a higher fabrication rate compared to the smaller strut lattice (< 2.00 mm). The designer also managed to improve the design up to 89% of part reductions and 50% of material reduction compared to the existing product design when using the TRIZ-AM approach. The CDRs applications were validated with capabilities such as design feature guide, size checking, either pass and fail outcomes. The case study reveals that TRIZ-AM method is beneficial in producing concept generation in early phases of PDD. In conclusion, the proposed method simplifies the design process in terms of build time, materials, weight, and prevents repetitive design iteration. It can also be useful to promote AM capabilities to amateur and professional designers based on TRIZ-AM design practice.