Design methodology for additive manufacturing using fused filament fabrication: failure theory, process chain and personalized application

The PhD thesis titled "Design Methodology for Additive Manufacturing using Fused Filament Fabrication: Failure Theory, Process Chain and Personalized Application" focuses on developing specific design methodologies for additive manufacturing (AM), with a primary emphasis on the Fused Filament Fabrication (FFF) process. The thesis is organized into four key chapters, each derived from an academic paper that addresses different aspects of Design for Additive Manufacturing (DFAM) and specifically Design for Fused Filament Fabrication (DF-FFF). 1. State of the Art on DFAM: The first article, "Design for additive manufacturing: a comprehensive review of the tendencies and limitations of methodologies," thoroughly examines existing methodologies in DFAM. It identifies the key areas of study, such as multi-objective optimization and functional performance. The article critiques the lack of radical innovation and the incomplete coverage of all design phases in the developed products. It emphasizes the need to include environmental and sustainability considerations in the existing methodologies. Additionally, it also highlights the importance of addressing limitations such as the mechanical reliability anisotropy of parts, process constraints, and product quality-issues that are further explored in the subsequent chapters/articles of the thesis. 2. DF-FFF with Failure Theory: The second article, "Design Methodology for Fused Filament Fabrication with Failure Theory: Framework, Database, Design rule, Methodology and Study of Case," introduces a methodology that integrates failure theory with DFAM practices specifically for FFF. This methodology seeks to improve product reliability and robustness by addressing the lack of failure theories integration in existing methodologies for functional parts. To validate this methodology, a prosthetic knee that failed under standard loads is redesigned, demonstrating several safe redesigns conceptually. 3. DF-FFF with Process Chain: The third article, "Design methodology for Fused Filament Fabrication with Process Chain: Framework, Database, Design rule, Methodology and Study of Case," develops a methodology that integrates DFAM with conventional process chains to enhance the quality of products manufactured with FFF. This approach aims to overcome typical limitations of FFF, such as finish, tolerances, and strength, while balancing cost benefits with improvements in product properties. To validate this methodology, a bone implant for cranioplasty is redesigned. The initial proposal addresses the lack of variety in materials and processes and the quantification of associated costs, while considering the biocompatibility and strength limitations of FFF-printed materials. 4. DF-FFF for Medical and Personalization Applications: The fourth article, "Design Methodology for Fused Filament Fabrication for Medical and Personalization Applications: Framework, Database, Design rule, Methodology and Study of Case," proposes a methodology for designing medical and personalized products using FFF. It highlights leveraging FFF’s advantages in terms of cost and time to improve the competitiveness and attractiveness of products in the market. The case of bone implants for cranioplasty is revisited to validate the methodology, incorporating customization and medical criteria, including design costs, to select the best alternative. Each of these articles contributes to the thesis with specific focus within the scope of DFAM, addressing various challenges and opportunities within the Fused Filament Manufacturing process. Together, they form a comprehensive foundation for future research and applications in additive manufacturing design.

• Autores: López Taborda, Luis Lisandro
• Tipo de recurso: Doctoral thesis
• Fecha de publicación: 2025
• Institución: Universidad del Norte
• Repositorio: Repositorio Uninorte
• Idioma: eng
• OAI Identifier: oai:manglar.uninorte.edu.co:10584/13577
• Acceso en línea: http://hdl.handle.net/10584/13577
• Palabra clave: Impresión digital
• Rights: openAccess
• License: https://creativecommons.org/licenses/by/4.0/