An approach to redesign of stainless steel handle for 3D metal printing
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Ruostumattomasta teräksestä valmistetun kahvan uudelleensuunnittelun lähestyminen metallin 3D tulostusta varten
The goal of this thesis, was to approach the redesign of a stainless-steel handle and to explore its most potential redesign targets, for manufacturing with the method of selective laser melting. Additionally, it was to be documented what challenges were met, what potential was found, what knowledge is needed, and what design guidelines could be followed to be able to find the potential and utilize the design freedom provided by SLM effectively. The thesis was carried out by performing literature review on the topic of DFAM and the SLM manufacturing method. The required knowledge and the challenge of the change of mindset was discussed. Compilations of the SLM design value network, SLM design recommendations, and things to consider in design for SLM were presented. A methodology to help identify feasible part candidates and evaluate their potential for AM production, and a methodology that defines steps to optimize mechanical systems with AM capabilities, were introduced. Additionally, practical design work was performed with the help of the compiled knowledge, the methodologies, and the suggested DFAM tools, to analyze and identify the potential redesign targets of the stainless-steel handle and derive the redesign examples of them. As a result, high amount of design potential for the stainless-steel handle was found. In total, 12 potentials of additional value that the SLM method could provide were identified, 7 redesign targets that could be achieved with full or a partial redesign were derived, and 5 redesign examples for the optimization of the current design were made. The thesis demonstrated that on an existing design, some parts can surely benefit from the design freedom provided by SLM as optimization, but the benefits on design are realized much more effectively with completely new designs started from a blank canvas. It was concluded, that not all parts can benefit from a design for SLM, and that recognizing part potential is essential, and that comprehensive methodological guidance on executing the utilization of design opportunities is lacking. It was recommended, that general design theory should be used and enriched with DFAM tools in the meantime. Additionally, recommendations for the utilization of the introduced methodologies were given.