In the search to understand functional capabilities and limitations of fused deposition modelling (FDM) manufactured components, control over their structural behaviour is crucial. For example, voids introduced during production phase are a large contributor anisotropy, yet magnitude this contribution remains unquantified. As baseline model for quantifying strength reduction due process-induced voids, statistical method evaluation minimum residual (net) cross section proposed tested. Our new...

This paper maps and describes how prototypes are used to elicit requirements of unknown unknowns in industry. Eight engineering design companies serve as a dataset for multi-case investigation. By semi-quantitatively analysing 19 terms functionality, timing, stakeholder involvement requirement elicitation, we present wide spectrum prototype utilizations. However, this broad span leads misunderstandings what the term 'prototype' encompasses, hindering exploitation its full potential. Hence,...

Abstract This study compares the design practices and performance of ChatGPT 4.0, a large language model (LLM), against graduate engineering students in 48-h prototyping hackathon, based on dataset comprising more than 100 prototypes. The LLM participated by instructing two participants who executed its instructions provided objective feedback, generated ideas autonomously made all decisions without human intervention. exhibited similar to finished second among six teams, successfully...

Prototyping is an important activity in most new product development processes. Whether the aim to explore opportunities or refine existing solutions, prototyping can be a valuable tool. This paper takes look at diversity of practices and contextual factors that may have impact on strategy. Through literature industrial as well academic case studies, several prevailing are identified used basis propose guidelines aid practitioners making decisions when formulating

The TrollLabs Open dataset includes comprehensive information that offers a comparison of design practices and outcomes between human participants Generative AI during hackathon event. was curated through the running prototyping designed to assess abilities performance generative AI, specifically ChatGPT, in early stages engineering design. This assessment involved comparing ChatGPT's experienced students setting, where competed by making prototype fires NERF dart as far possible. In this...

Physical prototypes have always been important in engineering design. However, little is known about the role that play development of complex physical products. This paper investigates and prototyping two novel product innovations recently launched by an automotive original equipment manufacturer (OEM). Through exploratory case study, are found to provide capability aid learning communication both within teams across organization. Actual prototype usage was encompass activities beyond...

The early phases of new product development have become an area increasing research interest during the past decades. vast majority researchers agree that potential for most substantial impact on innovation outcome lies in execution phases. In this paper, process seven automotive OEMs is studied. present work discusses general terms findings from sample companies, as well two in-depth reviews recent innovations launched by one OEMs; using semi-structured interviews. these case studies,...

Voids in fused deposition modeled (FDM) parts are assumed to be a key driver for their anisotropic behavior. However, these assumptions based on investigations of voids using only 2D data (microscopy images). This paper presents new method measure such by analyzing 3D-data from X-ray computed tomography (CT), and application this assessment mechanical parameters. The article is divided into three parts, where the first part elaborates proposed assess characterize void geometry throughout...

Material extrusion (MEX) is a well established production method in additive manufacturing. However, internal residual strains are accumulated during the layer-by-layer fabrication process. They bring about shape distortions and degradation of mechanical properties. In this paper, an in-situ distributed measurement MEX fabricated thermoplastic specimens achieved for first time. This innovative measuring system consists Optical Backscatter Reflectometry (OBR) interrogation unit connected to...

To print high-performance polymers, a stable running printer that can reach high temperatures is needed. There currently lack of low-cost solutions allow manipulation process parameters and expansion sensors to monitor the as well process. This paper presents an open-source hardware upgrade for 3D printers enable research on new high-temperature polymers manufacturing from all available polymers. The cost less than $1700, including printer. Open-source firmware by Klipper Fluidd used...

For parts manufactured by fused deposition modeling (FDM), helical threads drawn in accordance with normal standards (e.g. ISO 68-1), tend to end up deformed when manufactured. These dimensional imperfections typically include violation of radial tolerances and often distorted thread profile. Therefore, making successful threaded connections using FDM would require looser than standard ones, unless the nominal sections are very loose their tolerance band. As a proof-of-concept, this paper...

Prototypes are important tools in the development and production of new products. In engineering design literature, prototypes mainly perceived as for validating verifying aspects a late stages process. However, several studies have found that earlier well, it is currently unknown how contribute to add value within overall chains business system. Using case-study approach, we investigate this topic seeking answer question rapid prototyping various product process automotive industry. Based...

Purpose This paper aims to present the mathematical foundation of so-called advance algorithms , developed compensate for defects during acceleration and deacceleration print head in filament-based melt extrusion additive processes . It then investigates validity foundation, its performance on a low-cost system effect changing layer height algorithm’s associated process parameter. Design/methodology/approach study starts with compilation review literature algorithms, elaborates methods...

Purpose This paper proposes the combination of rapid prototyping and physical modelling as a set-based concept evaluation method in early stage new product development. Design/methodology/approach The is applied case study metal additive manufacturing process for aluminium, where set four extruder concepts has been modelled evaluated. Rapid was used to produce plastic models different designs, plasticine feedstock material physically model flow during operation. Finally, selected verified...

The TrollLabs Open dataset was created through the running of a prototyping hackathon designed to assess abilities and performance generative AI, particularly ChatGPT, in early stages engineering design. This assessment involved comparing ChatGPT's that experienced students setting, with aim making prototype fires NERF dart as far possible. comprises 116 entries 433 edges(connection) enables comparative analysis design practices between one team instructed solely by five teams consisting...

Abstract This article introduces a Human-centred Engineering Design (HcED) practice, which values human aspects. practice engages deeply into (1) geometry and motion for specific tasks, (2) product manufacturing complexities through rapid prototyping, (3) the broader task context. cross-disciplinary method combines ergonomics, AM, sensor applications, multiple design practices. The framework provides concrete tasks to drive innovative designs in engineering. study, grounded research case...

This paper demonstrates the unpredictability of outcomes that result from compounding variabilities when using generative design (GD) coupled with additive manufacturing (AM). AM technologies offer greatest freedom and hence are most able to leverage full capability tools thus maximize potential improvements, such as weight, waste cost reduction, strength, part consolidation. Implicit in all studies reported literature is fundamental assumption use GD, irrespective user experience or...

The current limitations of design for additive manufacturing (DfAM) are the state knowledge on materials and effects production parameters. As more engineering-grade polymers become available fused filament fabrication (FFF), designs processes must be adapted to fully utilize structural properties such materials. By studying comparing parameters a material test specimen component, layer temperature strength, surface roughness, dimensional accuracy PA6-CF were found. cross-section increases...

Throughout the whole product development process, there is always a question on whether proposed "up to its task", and often it up engineer or designer answer these questions. In many cases, this calls for experiments in form of prototype testing, explore, verify, validate performance. This paper connects overall approach point-based, set-based, agile strategies, them what seems be fundamental tradeoff experiments, exemplified by real cases from an industrial-academic project.

Abstract Composite filaments are getting increased attention in additive manufacturing (AM). More and better solutions for filament production needed to assist researchers discovering new materials capable of producing AM-made high-performance parts. This article presents a method composite filament, including an open-source, low-cost automatic feeder designed increase the accuracy quality filament. The includes fibre screw through iterative prototyping process accurately control filament's...