• Identify a traditionally-manufactured product, and adapt the product to be made via AM. Document & critically analyze each step of your process.

• Below is a rough guideline for how you may work through this project, but is not representative of all actions/analysis/determinations you may perform:

  • Product Selection:

    • Choose a product that is simple enough to allow a comprehensive analysis but complex enough to benefit from the advantages of AM.

    • Break down the product into its individual components, noting materials, connections, and the function of each part.

  • Design for Additive Manufacturing (DFAM) Analysis:

    • Identify necessary DFAM changes to optimize the product for AM processes, considering factors such as part consolidation, geometry optimization, and the elimination of unnecessary supports.

    • Redesign the product or components with AM in mind, focusing on minimizing assembly and utilizing the geometric freedom of AM.

  • Material Selection:

    • Select appropriate materials for AM that meet or exceed the properties of the original materials, including considerations for mechanical strength, flexibility, thermal resistance, and aesthetics.

    • Justify material choices based on their compatibility with the chosen AM process and the intended use of the product.

  • AM Process Selection:

    • Determine the most suitable AM process(es) for each component, considering factors such as material type, desired resolution, surface finish, and production volume.

    • Evaluate trade-offs between different AM processes, such as build time, cost, and post-processing requirements.

  • Cost Analysis:

    • Compare the estimated costs associated with traditional manufacturing and AM, taking into account the entire lifecycle of the product, from raw materials to end-of-life.

    • Consider how the changes in design, materials, and manufacturing processes impact the overall cost.

  • Sustainability Consideration:

    • Analyze the environmental impact of manufacturing the product traditionally versus using AM.

    • Discuss the potential for material reduction, energy efficiency, and recyclability with AM.

  • Prototype and Testing:

    • Create a prototype of the redesigned product using the selected AM process.

    • Conduct functional testing to ensure that the AM-produced product meets the required specifications and performance criteria.

To receive credit on this challenge, submit the URL link to the page on your portfolio website that documents your project