Change search
CiteExportLink to record
Permanent link

Direct link
Cite
Citation style
  • apa
  • ieee
  • modern-language-association-8th-edition
  • vancouver
  • Other style
More styles
Language
  • de-DE
  • en-GB
  • en-US
  • fi-FI
  • nn-NO
  • nn-NB
  • sv-SE
  • Other locale
More languages
Output format
  • html
  • text
  • asciidoc
  • rtf
A Design for Qualification Framework for the Development of Additive Manufacturing Components: A Case Study from the Space Industry
Luleå University of Technology, Department of Business Administration, Technology and Social Sciences, Humans and technology.ORCID iD: 0000-0002-3086-9140
2020 (English)In: Aerospace, ISSN 2226-4310, Vol. 7, no 3, article id 25Article in journal (Refereed) Published
Abstract [en]

Additive Manufacturing (AM) provides several benefits for aerospace companies in terms of efficient and innovative product development. However, due to the general lack of AM process understanding, engineers face many uncertainties related to product qualification during the design of AM components. The aim of this paper is to further the understanding of how to cope with the need to develop process understanding, while at the same time designing products that can be qualified. A qualitative action research study has been performed, using the development of an AM rocket engine turbine demonstrator as a case study. The results show that the qualification approach should be developed for the specific application, dependent on the AM knowledge within the organization. AM knowledge is not only linked to the AM process but to the complete AM process chain. Therefore, it is necessary to consider the manufacturing chain during design and to develop necessary knowledge concurrently with the product in order to define suitable requirements. The paper proposes a Design for Qualification framework, supported by six design tactics. The framework encourages proactive consideration for qualification and the capabilities of the AM process chain, as well as the continuous development of AM knowledge during product development.

Place, publisher, year, edition, pages
MDPI, 2020. Vol. 7, no 3, article id 25
Keywords [en]
additive manufacturing, design for additive manufacturing, verification, qualification, design for qualification, space industry
National Category
Other Engineering and Technologies not elsewhere specified
Research subject
Product Innovation
Identifiers
URN: urn:nbn:se:ltu:diva-77469DOI: 10.3390/aerospace7030025OAI: oai:DiVA.org:ltu-77469DiVA, id: diva2:1387427
Projects
Rymd för innovation och tillväxt (RIT)Radical Innovation and Qualification using Additive Manufacturing (RIQAM)
Funder
Swedish National Space Board
Note

Validerad;2020;Nivå 2;2020-03-31 (johcin)

Available from: 2020-01-21 Created: 2020-01-21 Last updated: 2020-03-31Bibliographically approved
In thesis
1. Qualification Aspects in Design for Additive Manufacturing: A Study in the Space Industry
Open this publication in new window or tab >>Qualification Aspects in Design for Additive Manufacturing: A Study in the Space Industry
2020 (English)Doctoral thesis, comprehensive summary (Other academic)
Abstract [en]

The aim of this research is to further the understanding of implications for product development and qualification when introducing additive manufacturing (AM) in the context of the space industry. Increased availability of AM machines and alluring potentials such as design freedom and cost-efficient product development and manufacturing has led to a rapid growth in the use of AM. However, the implementation of AM is hampered by lack of process understanding, implying uncertainties for engineers on how to design products for AM. Furthermore, the AM process chain (including e.g. post-processes) is not sufficiently developed and understood, adding further uncertainties. These uncertainties are a challenge when developing products for space applications, especially if they are critical for mission success and hence not allowed to fail. Such products and their manufacturing processes have to comply with strict requirements on verifying performance, quality, and reliability, i.e. product and process qualification. The purpose of this research is to investigate how qualification is addressed during product development in the space industry in order to find improved ways for engineers to explore the capabilities of AM to better understand its possibilities and limitations.

 

The research is specifically focused on the use of powder bed fusion processes by companies developing and manufacturing sub-system components for space applications. It is limited to the manufacturing of components on Earth for use in space. The research approach is qualitative. Five studies provide the empirical foundation for the thesis, in which a total of four companies are included. In particular, one of the companies is studied in-depth, including a development project for a critical AM product. Individual interviews, workshops and focus groups are used for data collection. Furthermore, the in-depth study is based on a longitudinal presence at the company, providing the opportunity to gather data from project meetings and discussions. Collaborative action research with three of the companies provides a research setting to study the development of three AM products (of which the in-depth study is one) and how uncertainties related to the AM process can be addressed.

 

Four aspects of how to address product qualification in Design for AM are deduced: (i) AM knowledge should be built through application-driven development processes, (ii) qualification should be accounted for early and to a larger extent, (iii) suitable and acceptable requirements should be defined through collaboration, and (iv) rapid manufacturing should be utilised to evaluate critical uncertainties. To support engineering teams on how to address these aspects, this thesis presents two contributions to the design field. The first is a design process utilising AM Design Artefacts (AMDAs) to identify, test and evaluate the AM-related uncertainties that are most pressing for a product. Through the iterative use of AMDAs, products designs are successively evolved, enabling a design which meets process capabilities and fulfils product requirements. The AMDA design process is part of the second contribution, a Design for Qualification framework that encourages a qualification-driven development approach for AM products. The framework includes six design tactics that provide guidance for its implementation. The tactics encourage an application-driven development process where qualification is considered early, and where successive steps are taken towards a thorough AM process chain understanding. The framework is designed based on the studied cases, and future research should focus on developing the framework and tactics further to facilitate implementation and wider applicability.

Place, publisher, year, edition, pages
Luleå University of Technology, 2020
Series
Doctoral thesis / Luleå University of Technology 1 jan 1997 → …, ISSN 1402-1544
Keywords
Additive Manufacturing, Design for Additive Manufacturing, Qualification, Design for Qualification, Space Industry
National Category
Other Engineering and Technologies Other Engineering and Technologies not elsewhere specified
Research subject
Product Innovation
Identifiers
urn:nbn:se:ltu:diva-77472 (URN)978-91-7790-520-2 (ISBN)978-91-7790-521-9 (ISBN)
Public defence
2020-03-17, A109, Luleå, 09:00 (English)
Opponent
Supervisors
Projects
Rymd för innovation och tillväxt (RIT)Radical Innovation and Qualification using Additive Manufacturing (RIQAM)
Funder
Swedish National Space BoardEuropean Regional Development Fund (ERDF)
Available from: 2020-01-22 Created: 2020-01-21 Last updated: 2020-03-30Bibliographically approved

Open Access in DiVA

fulltext(3379 kB)5 downloads
File information
File name FULLTEXT01.pdfFile size 3379 kBChecksum SHA-512
406895b0b3c407fa5f92465c6dd144d131397e3018ef5f4b85b2ed6d1f8b5246bc2906120f5db96df37938d968d85d0c087de92b81474e9e102a9bc21baab6f2
Type fulltextMimetype application/pdf

Other links

Publisher's full text

Authority records BETA

Dordlofva, Christo

Search in DiVA

By author/editor
Dordlofva, Christo
By organisation
Humans and technology
Other Engineering and Technologies not elsewhere specified

Search outside of DiVA

GoogleGoogle Scholar
Total: 5 downloads
The number of downloads is the sum of all downloads of full texts. It may include eg previous versions that are now no longer available

doi
urn-nbn

Altmetric score

doi
urn-nbn
Total: 118 hits
CiteExportLink to record
Permanent link

Direct link
Cite
Citation style
  • apa
  • ieee
  • modern-language-association-8th-edition
  • vancouver
  • Other style
More styles
Language
  • de-DE
  • en-GB
  • en-US
  • fi-FI
  • nn-NO
  • nn-NB
  • sv-SE
  • Other locale
More languages
Output format
  • html
  • text
  • asciidoc
  • rtf