University of Twente Student Theses
Developing a user-friendly design workflow for optimised designs in Direct Energy Deposition Additive Manufacturing at Royal Kaak
Roelofs, Stijn (2024) Developing a user-friendly design workflow for optimised designs in Direct Energy Deposition Additive Manufacturing at Royal Kaak.
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| Full Text Status: | Access to this publication is restricted |
| Embargo date: | 1 January 2027 |
| Abstract: | This thesis investigates what is needed to industrialise Direct Energy Deposition for Royal Kaak and how to integrate this into their current engineering process. Design rules and guidelines have internally been developed, but there has never been an attempt to create a complete workflow for an engineer. Royal Kaak does not want to use additive manufacturing to add value to high-tech components but use it to reduce carbon emissions and necessary welding hours for relatively low-tech products. Because of this, additional engineering costs cannot be justified, and the workflow has to be very user-friendly for their current personnel without strong background knowledge in the field. The products of Royal Kaak have been analysed, divided into four categories and additive manufacturing opportunities have been identified. Three design optimisation techniques have been explored accordingly: Topological Optimisation, Generative Design and Layout & Cross-section Optimisation. Due to its complexity, Topological Optimisation is outside the scope of this thesis and was left out of further research. For Generative Design and Layout & Cross-section Optimisation, workflows were developed. In Fusion360, a Generative Design workflow was developed. The outcomes proved that it is not possible to utilise this technique due to the limited control over the generation of the geometries. For Layout Optimisation, a Grasshopper script in Rhino was developed. Due to software limitations, this resulted in three script versions (A, B and C) with different functions and functionality. The Rhino workflow was validated by redesigning a part using Script B. The validation was completed successfully, and the connection nodes were printed. Rhino script B has the most potential for implementation. Using any shape-generating algorithm requires a very detailed setup of the design study. At Royal Kaak, designs are often created based on experienced engineers. It is very complex to transfer all the knowledge regarding unknown loads and accessibility to an algorithm. An engineer excels in understanding the entire functional environment. Therefore, an engineer should create a wire-frame design, and the individual elements are then optimised by Rhino’s script B. |
| Item Type: | Essay (Master) |
| Clients: | Royal Kaak, Terborg, Nederland |
| Faculty: | ET: Engineering Technology |
| Subject: | 52 mechanical engineering |
| Programme: | Mechanical Engineering MSc (60439) |
| Link to this item: | https://purl.utwente.nl/essays/98239 |
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