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A design for additive manufacturing case study: fingerprint stool on a BigRep ONE

A design for additive manufacturing case study: fingerprint stool on a BigRep ONE PurposeThis paper aims to present new qualitative and quantitative data about the recently released “BigRep ONE” 3 D printer led by the design of a one-off customized stool.Design/methodology/approachA design for additive manufacturing (DfAM) framework was adopted, with simulation data iteratively informing the final design.FindingsProcess parameters can vary manufacturing costs of a stool by over AU$1,000 and vary print time by over 100 h. Following simulation, designers can use the knowledge to inform iteration, with a second variation of the design being approximately 50 per cent cheaper and approximately 50 per cent faster to manufacture. Metrology data reveal a tolerance = 0.342 per cent in overall dimensions, and surface roughness data are presented for a 0.5 mm layer height.Research limitations/implicationsLed by design, this study did not seek to explore the full gamut of settings available in slicing software, focusing predominantly on nozzle diameter, layer height and number of walls alongside the recommended settings from BigRep. The study reveals numerous areas for future research, including more technical studies.Practical implicationsWhen knowledge and techniques from desktop 3 D printing are scaled up to dimensions measuring in meters, new opportunities and challenges are presented for design engineers. Print times and material costs in particular are scaled up significantly, and this study provides numerous considerations for research centers, 3 D printing bureaus and manufacturers considering large-scale fused filament fabrication manufacturing.Originality/valueThis is the first peer-reviewed study involving the BigRep ONE, and new knowledge is presented about the practical application of the printer through a design-led project. Important relationships between material volume/cost and print time are valuable for early adopters. http://www.deepdyve.com/assets/images/DeepDyve-Logo-lg.png Rapid Prototyping Journal Emerald Publishing

A design for additive manufacturing case study: fingerprint stool on a BigRep ONE

Rapid Prototyping Journal , Volume 25 (6): 11 – Jul 8, 2019

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References (36)

Publisher
Emerald Publishing
Copyright
Copyright © Emerald Group Publishing Limited
ISSN
1355-2546
DOI
10.1108/RPJ-10-2018-0278
Publisher site
See Article on Publisher Site

Abstract

PurposeThis paper aims to present new qualitative and quantitative data about the recently released “BigRep ONE” 3 D printer led by the design of a one-off customized stool.Design/methodology/approachA design for additive manufacturing (DfAM) framework was adopted, with simulation data iteratively informing the final design.FindingsProcess parameters can vary manufacturing costs of a stool by over AU$1,000 and vary print time by over 100 h. Following simulation, designers can use the knowledge to inform iteration, with a second variation of the design being approximately 50 per cent cheaper and approximately 50 per cent faster to manufacture. Metrology data reveal a tolerance = 0.342 per cent in overall dimensions, and surface roughness data are presented for a 0.5 mm layer height.Research limitations/implicationsLed by design, this study did not seek to explore the full gamut of settings available in slicing software, focusing predominantly on nozzle diameter, layer height and number of walls alongside the recommended settings from BigRep. The study reveals numerous areas for future research, including more technical studies.Practical implicationsWhen knowledge and techniques from desktop 3 D printing are scaled up to dimensions measuring in meters, new opportunities and challenges are presented for design engineers. Print times and material costs in particular are scaled up significantly, and this study provides numerous considerations for research centers, 3 D printing bureaus and manufacturers considering large-scale fused filament fabrication manufacturing.Originality/valueThis is the first peer-reviewed study involving the BigRep ONE, and new knowledge is presented about the practical application of the printer through a design-led project. Important relationships between material volume/cost and print time are valuable for early adopters.

Journal

Rapid Prototyping JournalEmerald Publishing

Published: Jul 8, 2019

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