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- Dordlofva, Christo
(författare)
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Qualification Aspects in Design for Additive Manufacturing : A Study in the Space Industry
- 2020
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Doktorsavhandling (övrigt vetenskapligt/konstnärligt)abstract
- 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.
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| 2. |
- Wikberg Nilsson, Åsa, et al.
(författare)
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Experiences of educational reform : Implementation of cdio at industrial design engineering
- 2017
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Ingår i: Proceedings of the 13th International CDIO Conference, University of Calgary, Calgary, Canada, June 18-22, 2017, University of Calgary Press, 2017. - Calgary : University of Calgary Press.
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Konferensbidrag (refereegranskat)abstract
- Luleå University of Technology (LTU) joined the CDIO initiative in 2015. The development of the MSc program Industrial Design Engineering (IDE) was one of LTU’s four test pilots of educational reform with support of the CDIO framework. The current educational reform comprises all CDIO standards, however some have been easier to implement than others. The results from the current CDIO-implementation are so far positive experiences from both faculty and students. While the program curriculum has been developed at a macro level, changes also impact the program objectives, teachers’ skills development, and students’ learning outcomes at a micro level where, for example, courses have been redesigned regarding teaching and learning activities, and assessments have been developed to include both formative and summative feedback to promote a deep learning approach. Great efforts have also been put into development of new learning environments, finalized in 2016. However, implementation of CDIO also deals with changing the educational culture, a work that takes more efforts and time than just one year. A success factor in the current implementation is the involvement of experienced CDIO-implementers that have inspired, motivated and coached the IDE faculty in re-designing the program.
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| 5. |
- Bergström, Mattias, et al.
(författare)
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Examining creative collaboration in distributed and co-located design teams
- 2007
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Ingår i: Design for society. - Paris : Design Research Society.
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Konferensbidrag (refereegranskat)abstract
- Product development, including all its phases, is today performed to a greater extent in globally dispersed teams. This paper compares two creative design sessions early in the product development process, one co-located session and one distributed session. The workflow in the co-located session was fluid and natural, whereas in the distributed session, it was sometimes disturbed by limitations ofthe mediating technology. The major deficiencies of the technology are the limited support for shared drawing surfaces, for shared control of these surfaces and for creation of concepts. In the co-located session embodied representation were used to describe, communicate and build upon concepts. Due to the limitations of the technology, these types of communication were seldom used in the distributedsession.
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| 6. |
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| 7. |
- Bergström, Mattias, et al.
(författare)
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Sharing the unshareable : distributed product review using tangibles
- 2005
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Ingår i: Proceedings. - Berlin : VDE-Verlag. - 3800728834 ; , s. 161-175
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Konferensbidrag (refereegranskat)abstract
- Due to the ongoing globalization of businesses and the collaboration occurring between geographically dispersed organizations, distributed collaborative work using computer based support tools becomes increasingly important. When trying to perform design work while relying heavily on the use of physical artefacts such as early mock-ups, a need to share the unshareable, i.e. physical objects, will inevitably occur in a distributed setting. In an attempt to realize this, the authors studied a design team during their design reviews where a physical mock-up was used. A wearable conferencing unit (the Boblebee computer) was then developed to give remote collaborators a first person view of the mock-up using a head mounted video camera. With the Boblebee computer, remote collaboration with large tangible objects can successfully be realized. This paper relates experiences from the design of the system, and reports on early observations of its use.
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| 8. |
- Bergström, Mattias, et al.
(författare)
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Towards virtual co-location in functional product development
- 2008
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Ingår i: Collaboration and the Knowledge Economy. - : IOS Press. - 9781586039240 - 9781905824090 ; , s. 806-814
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Konferensbidrag (refereegranskat)abstract
- The shift in industry towards Functional Product Innovation implies more collaborative efforts between the partners forming joint ventures, i.e. cross-company collaboration. Hence, new demands are put on collaborative technology. Insights into needs for both industry and collaborative design teams provide the possibilities for ‘virtual co-location' to be enhanced. Following a workshop format, the radical innovation workshop, industrial criterions for collaborative technology has been analyzed based on empirical data from five Swedish manufacturing companies. During the workshop three scenarios were put forward by the industry as most relevant; (1) the design review, (2) to on-site remotely collaborate with an expert and (3) the day-to-day communication. Based on these scenarios, three industrial criterions emerged, namely efficient collaboration, effortless setup of communication and the capability to create trust without touch. Technologies to support Functional Product Innovation seem to insist on meeting these criterions.
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| 9. |
- Dordlofva, Christo, et al.
(författare)
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Design for Qualification : A Process for Developing Additive Manufacturing Components for Critical Systems
- 2018
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Ingår i: Proceedings of NordDesign: Design in the Era of Digitalization. - 9789176851852
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Konferensbidrag (refereegranskat)abstract
- Additive Manufacturing (AM), and more specifically Powder Bed Fusion, offers design freedom, functional integration, and cost efficient manufacturing of customised products. These design and manufacturing capabilities are relevant for the space industry with its characteristic low production volumes, high-performance products, pursuit for low weight, and a recent need for cost reduction due to increased market competition. At the same time, the space industry is characterised by products in harsh environments without room for failure, nor the possibility to repair broken parts in service. Product qualification is therefore an important part of the product development process in the space industry, with the purpose of showing that the product design and its manufacturing process fulfils the technical requirements. Qualification is a challenge for AM that currently exhibits a sensitivity in part mechanical properties based on geometry and build orientation, as well as a variability in process outcome. As with other manufacturing processes, design engineers have to take process capabilities into account during product design to render a manufacturable product (Design for AM), but also to achieve the right quality and function (Design for Excellence). Apart from manufacturability, product qualification has to be considered early in the product development process of AM parts. Given the lack of understanding of AM process characteristics, design engineers are in need of design supports to facilitate the qualification of critical AM parts. This paper presents a Design for Qualification process model for development of AM components in critical space systems. The model is proposed based on research performed in the space industry with several case companies.
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| 10. |
- Dordlofva, Christo, et al.
(författare)
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Evaluating design uncertainties in additive manufacturing using design artefacts : examples from space industry
- 2020
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Ingår i: Design Science. - : Cambridge University Press. - 2053-4701. ; 6
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Tidskriftsartikel (refereegranskat)abstract
- The use of metal Additive Manufacturing (AM) has increased in recent years with potential benefits for novel design solutions and efficient manufacturing. In order to utilise these potentials, engineers need to address uncertainties related to product design and the AM process. This paper presents a design process utilising product-specific AM Design Artefacts (AMDAs) to assess uncertainties identified during design. The process emphasises the importance of concurrently developing the product and AM knowledge. Based on a research collaboration with industry, three case studies describe the use of this process in the development of products for AM. In total, six different types of AMDAs show how AM-related uncertainties are resolved to provide confidence in design solutions and manufacturability. The contributions of this paper are: (i) a design process where AMDAs are used as support in evolving and defining an AM design specification, (ii) an example of how Design for AM (DfAM) is practiced in industry and of typical AM uncertainties that are encountered and addressed, and (iii) an example of how collaborative research can facilitate new knowledge for both industry and academia. The practical implication is a DfAM process for engineers to use and adapt according to existing AM knowledge.
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