Digital design automation to support in-situ embedding of functional components in additive manufacturing

Manoj Malviya, Swapnil Sinha, Nicholas A. Meisel

Research output: Chapter in Book/Report/Conference proceedingConference contribution

Abstract

Additive manufacturing (AM) offers access to the entire volume of a printed artifact during the build operation. This makes it possible to embedding foreign components (e.g. sensors, motors, actuators) into AM parts, thus enabling multifunctional products directly from the build tray. However, the process of designing for embedding currently requires extensive designer expertise in AM. Current methods rely on a designer to select an orientation for the embedded component and design a cavity such that the component can be successfully embedded without compromising the print quality of the final part. For irregular geometries, additional design knowledge is required to prepare a shape converter: a secondary piece to ensure a flush deposition surface on top of the embedded component. This research aims to develop a tool to automate these different design decisions for in-situ embedding, thus reducing the need for expert design knowledge. A three-stage process is proposed to 1) find the optimum orientation based on cavity volume and cross-section area, 2) create the necessary cavity geometry to successfully insert the component, and 3) perform a Boolean operation to create the digital design for any requisite shape converter. Performance of the tool is demonstrated with four test cases with varying levels of geometric complexity. These test cases show that the proposed process successfully handles arbitrary embedded geometries, though several limitations are noted for future work.

Original languageEnglish (US)
Title of host publication45th Design Automation Conference
PublisherAmerican Society of Mechanical Engineers (ASME)
ISBN (Electronic)9780791859186
DOIs
StatePublished - Jan 1 2019
EventASME 2019 International Design Engineering Technical Conferences and Computers and Information in Engineering Conference, IDETC-CIE 2019 - Anaheim, United States
Duration: Aug 18 2019Aug 21 2019

Publication series

NameProceedings of the ASME Design Engineering Technical Conference
Volume2A-2019

Conference

ConferenceASME 2019 International Design Engineering Technical Conferences and Computers and Information in Engineering Conference, IDETC-CIE 2019
CountryUnited States
CityAnaheim
Period8/18/198/21/19

All Science Journal Classification (ASJC) codes

  • Mechanical Engineering
  • Computer Graphics and Computer-Aided Design
  • Computer Science Applications
  • Modeling and Simulation

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  • Cite this

    Malviya, M., Sinha, S., & Meisel, N. A. (2019). Digital design automation to support in-situ embedding of functional components in additive manufacturing. In 45th Design Automation Conference (Proceedings of the ASME Design Engineering Technical Conference; Vol. 2A-2019). American Society of Mechanical Engineers (ASME). https://doi.org/10.1115/DETC2019-97607