| 1. |
- Borgue, Olivia, 1989
(författare)
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Affordable identification and modelling of uncertain design specifications when introducing new technologies in space applications
- 2021
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Doktorsavhandling (övrigt vetenskapligt/konstnärligt)abstract
- When introducing new technologies in space products, both the uncertainties regarding technology feasibility and the way in which the technology affects the product development process hinder the early establishment of appropriate engineering specifications. Failing to establish product specifications during conceptual stages leads to problems discovered during later phases of the product development process, when design and process changes are the most expensive. This thesis proposes a digital holistic design platform and a method of constraints replacement for a cost- and time-efficient identification of specification uncertainties when designing space products with new technologies. The digital platform and methods have been developed and tested through industrial case studies featuring the introduction of new technologies for on-orbit applications. Most of these studies were performed in the context of, but are not limited to, the introduction of additive manufacturing. The platform and proposed constraints replacement method are based on function modeling strategies (for modeling product architecture and requirements during conceptual design phases), coupled with activity modeling strategies (for modeling the impact of product architecture on product development schedules and costs). The platform and method enable the identification and assessment of unknown uncertainties, thereby reducing the likelihood of expensive redesign processes during later development phases. Moreover, they enable the inclusion of multidisciplinary design trade-offs during conceptual stages and encourage the establishment of a culture of uncertainty seeking and effective data documentation and transfer.
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| 2. |
- Borgue, Olivia, 1989, et al.
(författare)
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Constraint Replacement-Based Design for Additive Manufacturing of Satellite Components: Ensuring Design Manufacturability through Tailored Test Artefacts
- 2019
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Ingår i: Aerospace. - : MDPI AG. - 2226-4310. ; 6:11
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Tidskriftsartikel (refereegranskat)abstract
- Additive manufacturing (AM) is becoming increasingly attractive for aerospace companies due to the fact of its increased ability to allow design freedom and reduce weight. Despite these benefits, AM comes with manufacturing constraints that limit design freedom and reduce the possibility of achieving advanced geometries that can be produced in a cost-efficient manner. To exploit the design freedom offered by AM while ensuring product manufacturability, a model-based design for an additive manufacturing (DfAM) method is presented. The method is based on the premise that lessons learned from testing and prototyping activities can be systematically captured and organized to support early design activities. To enable this outcome, the DfAM method extends a representation often used in early design, a function-means model, with the introduction of a new model construct-manufacturing constraints (Cm). The method was applied to the redesign, manufacturing, and testing of a flow connector for satellite applications. The results of this application-as well as the reflections of industrial practitioners-point to the benefits of the DfAM method in establishing a systematic, cost-efficient way of challenging the general AM design guidelines found in the literature and a means to redefine and update manufacturing constraints for specific design problems.
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| 3. |
- Borgue, Olivia, 1989, et al.
(författare)
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Design for test and qualification through activity-based modelling in product architecture design
- 2021
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Ingår i: Journal of Engineering Design. - : Informa UK Limited. - 1466-1837 .- 0954-4828. ; 32:11, s. 646-670
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Tidskriftsartikel (refereegranskat)abstract
- Test and qualification (T&Q) phases take a significant portion of the time to market for critical products in the space industry, especially when introducing new technologies. Since T&Q are treated as standard procedures, they tend to be independent of the architectural design phases and kept away from design decisions. However, when introducing new technologies, qualification procedures may differ from those established in regular design scenarios, and the estimation of qualification costs and duration is problematic. There is a lack of design for qualification methods capable of modelling these activities in early phases and use those models to support the architecture design of products with affordable test and qualification phases. In this article, a computer-assisted, model-based design method to model T&Q activities concerning early product architecture designs is proposed. Product architecture alternatives, test schedules and cost are connected through the quantification of T&Q drivers and driver rates. The design method is demonstrated using a case study about electric propulsion for satellites. The method is applicable for design situations where the choice of technology has a strong dependence on the qualification procedure.
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| 4. |
- Borgue, Olivia, 1989, et al.
(författare)
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Function modelling and constraints replacement for additive manufacturing in satellite component design
- 2018
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Ingår i: Proceedings of NordDesign: Design in the Era of Digitalization, NordDesign 2018.
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Konferensbidrag (refereegranskat)abstract
- Additive Manufacturing is increasingly attracting interest among manufacturers of space components, mainly due to its high design freedom, capability for achieving weight reduction and for being cost-efficiently produced in low volumes. However, AM is a less mature technology compared to established manufacturing methods. This lack of maturity concerns especially the area of AM manufacturing constraints as the knowledge about them is limited and because they mature over time, as the technology evolves. The lack of knowledge hinders designers to fully take advantage of AM, fearing that the technology will affect product reliability. This situation is particularly emphasized in space components, since they are subject to high reliability requirements. In this paper, a methodology based on function decomposition and constraint modelling is proposed as a basis for re-design of products using AM. In the methodology, the original functions, design solutions and manufacturing constraints of a product are identified. Then, the original manufacturing constraints are removed and replaced with manufacturing constraints for AM. Afterwards, functions and design solutions on the function model are modified and a new part geometry is designed and eventually realised in CAD. This methodology has been applied on a case study featuring a satellite sub-component.
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| 5. |
- Borgue, Olivia, 1989, et al.
(författare)
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Function modelling and constraints replacement to support design for additive manufacturing of satellite components
- 2018
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Ingår i: Proceedings of NordDesign: Design in the Era of Digitalization, NordDesign 2018.
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Konferensbidrag (refereegranskat)abstract
- © Proceedings of NordDesign: Design in the Era of Digitalization, NordDesign 2018. All rights reserved. Additive Manufacturing is increasingly attracting interest among manufacturers of space components, mainly due to its high design freedom, capability for achieving weight reduction and for being cost-efficiently produced in low volumes. However, AM is a less mature technology compared to established manufacturing methods. This lack of maturity concerns especially the area of AM manufacturing constraints as the knowledge about them is limited and because they mature over time, as the technology evolves. The lack of knowledge hinders designers to fully take advantage of AM, fearing that the technology will affect product reliability. This situation is particularly emphasized in space components, since they are subject to high reliability requirements. In this paper, a methodology based on function decomposition and constraint modelling is proposed as a basis for re-design of products using AM. In the methodology, the original functions, design solutions and manufacturing constraints of a product are identified. Then, the original manufacturing constraints are removed and replaced with manufacturing constraints for AM. Afterwards, functions and design solutions on the function model are modified and a new part geometry is designed and eventually realised in CAD. This methodology has been applied on a case study featuring a satellite sub-component.
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| 6. |
- Borgue, Olivia, 1989, et al.
(författare)
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Fuzzy model-based design for testing and qualification of additive manufacturing components
- 2022
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Ingår i: Design Science. - : Cambridge University Press (CUP). - 2053-4701. ; 8
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Tidskriftsartikel (refereegranskat)abstract
- The uncertainties and variation of additive manufacturing (AM) material properties and their impact on product quality trouble designers. The lack of experience in AM technologies renders the experts' assessment of AM components and the establishment of safety margins difficult. Consequently, unexpected qualification difficulties resulting in expensive and lengthy redesign processes might arise. To reduce the risk of qualification failure, engineers might perform copious time-consuming and expensive specimen testing in early phases, or establish overconservative design margins, overriding the weight reduction benefits of AM technologies. In this article, a model-based design method is proposed for the conceptual design of AM space components with affordable test phases. The method utilizes fuzzy logics to systematically account for experts' assessment of AM properties variation, and to provide an early estimation of a product qualification likelihood related to design parameters of interest, without the need for copious testing. The estimation of qualification likelihood can also point out which are the unique AM material uncertainties that require further specific testing, to enable the design of a product with a better performance and more affordable test phases. The method is demonstrated with the design for AM gridded of ion thrusters for satellite applications.
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| 7. |
- Borgue, Olivia, 1989, et al.
(författare)
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Impact on design when introducing additive manufacturing in space applications
- 2018
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Ingår i: Proceedings of International Design Conference, DESIGN. - : Faculty of Mechanical Engineering and Naval Architecture, University of Zagreb, Croatia; The Design Society, Glasgow, UK. - 1847-9073. - 9789537738594 ; 3, s. 997-1008
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Konferensbidrag (refereegranskat)abstract
- This paper studied how the introduction of additive manufacturing (AM) in space applications impacts the design phases. Together with three manufacturers of space applications, the potential benefit as well as constraints are studied to identify design gaps. A literature survey is conducted to match the needs and following an analysis the impact on design practice is formulated. Results show the need to combine a wider design exploration capability, in combination with comparative modelling strategies.
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| 8. |
- Borgue, Olivia, 1989, et al.
(författare)
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Model-based design of AM components to enable decentralized digital manufacturing systems
- 2021
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Ingår i: Proceedings of the International Conference on Engineering Design, ICED. - : Cambridge University Press (CUP). - 2220-4334 .- 2220-4342.
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Konferensbidrag (refereegranskat)abstract
- Additive manufacturing (AM) is a versatile technology that could add flexibility in manufacturing processes, whether implemented alone or along other technologies. This technology enables on-demand production and decentralized production networks, as production facilities can be located around the world to manufacture products closer to the final consumer (decentralized manufacturing). However, the wide adoption of additive manufacturing technologies is hindered by the lack of experience on its implementation, the lack of repeatability among different manufacturers and a lack of integrated production systems. The later, hinders the traceability and quality assurance of printed components and limits the understanding and data generation of the AM processes and parameters. In this article, a design strategy is proposed to integrate the different phases of the development process into a model-based design platform for decentralized manufacturing. This platform is aimed at facilitating data traceability and product repeatability among different AM machines. The strategy is illustrated with a case study where a car steering knuckle is manufactured in three different facilities in Sweden and Italy.
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| 9. |
- Borgue, Olivia, 1989
(författare)
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Modelling the integration of Additive Manufacturing technologies in design for space components
- 2019
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Licentiatavhandling (övrigt vetenskapligt/konstnärligt)abstract
- Products for space applications are traditionally costly and produced in small batches. Moreover, they must be able to withstand extreme environments and meet tough requirements when in operation, as the ability to maintain and repair them is limited. However, nowadays cost and lead time reduction are becoming important driving forces for space manufacturers. New technologies such as Additive manufacturing (AM) are attractive for space companies as they enable new product functionalities or lower production costs, fostering company capabilities and permanence in the market. However, the lack of knowledge and experience in AM hinders its implementation in highly regulated industries such as the space industry. In this thesis, a first approach of a model-based Design for Additive Manufacturing (DfAM) design support is presented to facilitate the introduction of AM in components for space applications. The design support aims at redesigning components for AM, taking advantage of AM design freedom but considering AM limitations as well. Moreover, to address the needs of the space industry, relevant design trade-offs of space products, such as weight/cost reduction, component modularity or adaptability to market changes are included in the DfAM design support. The applicability of the design support has been demonstrated in the design of different space products (such as satellite antennas) and in the context of three different Swedish manufacturers of space components. A first validation of the design support and the redesigned space components was performed with industrial practitioners. The proposed design support was developed for the introduction of a new manufacturing technology in space components. As technologies for space applications advance at a fast pace, future research needs to be performed to adapt the design support to enable the introduction of technologies that are not manufacturing related. Moreover, as product development is often concerned with the introduction of multiple technologies in the same product/product family, the impact of technology interactions in product design is of interest and will be studied further.
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| 10. |
- Borgue, Olivia, 1989, et al.
(författare)
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Modular product design for additive manufacturing of satellite components: maximising product value using genetic algorithms
- 2019
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Ingår i: Concurrent Engineering Research and Applications. - 1063-293X .- 1531-2003. ; 27:4, s. 331-346
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Tidskriftsartikel (refereegranskat)abstract
- For space manufacturers, additive manufacturing promises to dramatically reduce weight and costs by means of integral designs achieved through part consolidation. However, integrated designs hinder the ability to change and service components over time - actually increasing costs - which is instead enabled by highly modular designs. Finding the optimal trade-off between integral and modular designs in additive manufacturing is of critical importance. In this article, a product modularisation methodology is proposed for supporting such trade-offs. The methodology is based on combining function modelling with optimisation algorithms. It evaluates product design concepts with respect to product adaptability, component interface costs, manufacturing costs and cost of post-processing activities. The developed product modularisation methodology is derived from data collected through a series of workshops with industrial practitioners from three different manufacturer companies of space products. The implementation of the methodology is demonstrated in a case study featuring the redesign of a satellite antenna.
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