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Module 1: Design and Supply Chain for Additive Manufacturing

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Design and Supply Chain for Additive Manufacturing - Lesson Summary

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The key points from this module are:

Benefits of Additive Manufacturing include:
Reduced product development cycle time
Opens design space
Material saving
Reduces cost for complex parts
Reduces inventory

Applications of Additive Manufacturing:
Prototyping - Customer demos
Tooling - Assembly tools and fixtures
Production - New design, Legacy parts.
Part Repair - Worn out parts, Design mods.

Importance of Design for Additive Manufacturing (DFAM):
To leverage freeform fabrication enabled by Additive Manufacturing
To make design suitable for Additive Manufacturing with minimum supports.
To minimize post-processing
Design can be produced with consistency and reliability

Design for Additive Manufacturing (DFAM) Approach are:
System Design - Choose component for AM, Define design problem, Define material load cases, etc.
Part Design - Creation and interpretation of initial design, Verification of design, etc.
Process Design - Creation and evaluation of support structure, AM preparation, Validation of build time and cost, AM Simulation.

Advantages of Additive Manufacturing Supply Chain include:
Enables more complexity in design
Time to market is shorter
Lower inventory and lesser materials
Closer to markets
Becoming agile

Challenges and Limitations of Additive Manufacturing include:
Dimensional Accuracy
Surface Roughness
Build Quality
Part Size
Material

Comparison of Traditional and Additive Manufacturing Supply Chain models
Traditional Supply Chain
- Mass production
- Manufactured goods are "pushed out" to customers
- Distributed through warehouse networks to customers
- Long lead time
- High transport costs
- Large carbon footprint
AM Supply Chain- Customized production
- Goods are "pulled" by end customers demands
- Locally printed and distributed
- Short lead time
- Low transport costs
- Minimal carbon footprint
- Raw material (powder) inventory management

Design for Excellence (DFX) is a strategy adopted with the objective of optimizing product along with production system to reduce development time and cost, and also enhance performance quality and profitability.

Design for Excellence categories:
Design - Materials, Safety Margin, Weight, etc.
Manufacturing - Casting, Printing, Finishing, etc.
Quality - 3D scanning, Impact test, Fixture Gauges, etc.
Assembly - Welding, Fasteners, Slide fit, etc.

Impact of Value Addition Through Additive Manufacturing Benefits:
Process Benefits: Less process time, Better surface quality, Higher benefits, Dimensional accuracy.
Economic Benefits: Higher productivity, Cost reduction, Reduced inventory and assembly effort.
Performance Benefits: Lightweight, Efficient Heat Transfer, Functional Integration, Increased stiffness.