MAE Seminar: Design for Metal Additive Manufacturing - Three Use Cases and Their Implications
Paul Morrow Professor of Engineering Design & Manufacturing
The Pennsylvania State University
Abstract: A pattern is emerging among companies adopting metal-based additive manufacturing (AM). In the first stage, they use AM to replicate an existing part to understand the technology’s costs and capabilities. This gives them insight into AM processes and allows them to move onto the second stage wherein they adapt their designs for AM to reap additional benefits by leveraging the design and material freedoms that AM affords. Finally, companies eventually shift to optimizing for AM as they gain confidence in an AM process while learning how to capitalize on AM to its full potential. These three stages can be effective when designing for AM, but only if expectations are carefully managed at each stage. Automotive, aerospace, consumer goods, and oil and gas examples from Penn State’s Center for Innovative Materials Processing through Direct Digital Deposition (CIMP-3D) are presented to illustrate the benefits and drawbacks of each stage. CIMP-3D began as the Manufacturing Demonstration Facility (MDF) for Additive Manufacturing for DARPA’s Open Manufacturing Program. In this role, CIMP-3D conducted tours for more than 6,000 visitors, organized a dozen technical forums and exchanges, and instituted the first hands-on industry practicum for metal AM. Efforts to educate the next generation workforce and (re)train the current workforce to use AM effectively and design for AM will also be discussed.
Bio: Tim Simpson is the Paul Morrow Professor of Engineering Design & Manufacturing, director of the world’s first Additive Manufacturing and Design graduate program, and co-director of the Center for Innovative Materials Processing through Direct Digital Deposition (CIMP-3D) at Penn State. He has received more than $50M in support of his research and teaching initiatives, and he has published more than 350 peer-reviewed papers in journals and conference proceedings and served as lead editor on two textbooks. He specializes in design for additive manufacturing, and he has helped educate and train more than 700 industry practitioners to use metal additive manufacturing. He contributes a monthly column entitled, “Additive Insights,” to Modern Machine Shop, and he is an ADDVisorSM for The Barnes Global Advisors, a team of experts helping industrialize additive manufacturing. He has received numerous awards for outstanding research and teaching at Penn State, including the 2019 Teaching and Learning with Technology Impact Award for helping bring 3D printing to all 100,000 Penn State students. He is a recipient of ASME’s Dedicated Service Award, Design Automation Award, Robert E. Abbott Award and Ben C. Sparks Award as well as the ASEE Fred Merryfield Design Award. He is a fellow in ASME and an associate fellow in AIAA. He received his Ph.D. and M.S. in mechanical engineering from Georgia Tech and his B.S. in mechanical engineering from Cornell.