Computer-Aided Design and Additive Manufacturing for Automotive Prototypes: A Review
Abstract
:Featured Application
Abstract
1. Introduction
2. Material and Methods
2.1. Identification of Relevant Studies
- Explicit discussion of the integration of CAD and AM in prototypes.
- Qualitative studies using CAD systems to support AM in the manufacturing process.
- Articles with key terms matching the title and abstract or keywords.
- Academic journal articles.
- All references that occurred in the search were delimitated from 2015 to 2023.
- Papers are written in the English language.
2.2. Screening and Selection Process
Descriptive Analysis
2.3. Essential Features of Current Research
2.3.1. Advanced Manufacturing Techniques and Materials
2.3.2. Optimization and Performance Enhancement
2.3.3. Challenges and Industry Hesitancy
2.3.4. Innovative Approaches in CAD and AM
2.3.5. Process Optimization and Quality Enhancement
2.3.6. Use of AM in Diverse Industries
2.3.7. Challenges in Adopting AM Techniques
2.3.8. Customer-Centric Design Approaches in AM
2.3.9. Optimization and Performance Enhancement in AM
2.4. Design Framework
Conceptualization of the Design Principles
3. Results and Discussions
Empirical Investigations and Original Contributions
4. Conclusions
Author Contributions
Funding
Institutional Review Board Statement
Informed Consent Statement
Data Availability Statement
Acknowledgments
Conflicts of Interest
References
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Research Area | Authors | Consensus/Innovative Solutions | Emerging Trends | Impact on CAD | Impact on AM | Implications for Further Developments |
---|---|---|---|---|---|---|
Advanced Manufacturing Techniques and Materials | [32] | Balancing the innovative potential of AM in creating complex CHX structures against design accuracy and thermal efficiency challenges. | Integration of 3D printing in thermal management solutions. | Synergy between CAD design, computational fluid dynamics, and AM. | Enhances the application of CAD in designing and optimizing 3D-printed jigs. | Findings can influence the design of machine elements using MEX technology and guide future research in 3D-printing material properties. |
[33] | Industry’s hesitancy toward 3D-printed materials due to the lack of standardization in torsional strength contrasts with the potential of MEX technology for varied applications. | Increasing use of 3D printing for complex internal structures, focusing on mechanical properties of 3D printed materials. | Enhances understanding of material behavior in 3D printing, supporting better CAD modeling for AM. | Contributes to material databases for FEA Autodesk software-Nastran 2021. | Findings can guide future research in 3D-printing material properties. | |
[24] | While 3D printing offers advantages in manufacturing jigs, systematic studies are needed to determine how different printing parameters affect their performance. | Increased application of 3D printing to produce functional manufacturing tools like jigs. | Enhances the application of CAD in designing and optimizing 3D-printed jigs, integrating thermomechanical properties. | Emphasis on optimizing thermomechanical properties of jigs. | Findings can guide the designing and manufacturing of more efficient and tailored jigs using 3D-printing technologies. | |
Optimization and Performance Enhancement | [20] | While rapid prototyping offers flexibility and efficiency, this paper discusses the challenges of achieving high performance in pneumatic valves. | Growing use of rapid prototyping in industrial applications. | Demonstrates the integration of CAD and computational fluid dynamics simulations in rapid prototyping. | Enhances the development process of industrial components. | Highlights the potential of rapid prototyping in producing high-performance industrial components. |
[34] | Balancing the potential of AM with its challenges, especially regarding process limitations, material selection, and design constraints. | Increasing role of additive manufacturing in meeting the demands of customized and high-quality product manufacturing. | Highlights the need for integrated design and manufacturing approaches in the context of AM. | Contributes to understanding how to effectively integrate AM technologies into the manufacturing sector. | Emphasis on the integration of AM in supply chain dynamics. | |
[35] | Discusses the efficiency of TO and GD in AM and their integration with CAD. | Focus on integrating TO and GD tools in AM for improved design and manufacturing. | Highlights the need for better integration of optimization tools with CAD systems for AM. | Suggests a potential shift in design approaches for AM, emphasizing optimization tools. | Emphasis on the integration of TO and GD tools in AM for improved design and manufacturing. | |
Challenges and Industry Hesitancy | [36] | Industry’s adaptation to new RPS methods and their potential to revolutionize micro-manufacturing. | Integration of inkjet technology in RPS for higher precision and efficiency in micro-manufacturing. | Proposes a more precise and efficient RPS technology. | Transformation in micro-manufacturing industries. | Highlights the potential transformation in micro-manufacturing industries with enhanced RPS technology. |
[37] | Balance between rapid prototyping advantages and challenges of integrating new technologies like AM and HIL in vehicle development. | Increasing use of AM in-vehicle prototyping and role of HIL in powertrain development. | Showcases the potential of AM and HIL in reducing development time and enhancing flexibility. | Insights into the application of emerging technologies in the automotive sector. | Significant advancement in vehicle development processes. | |
[22] | Growing adoption of AM in mature engineering fields like automotive engineering, addressing advantages and challenges. | Emphasis on using 3D printing and generative design in the automotive industry. | Integration of generative design and AM in automotive manufacturing. | Potential to revolutionize the automotive manufacturing process. | Highlights the potential of AM in revolutionizing the automotive manufacturing process. | |
[38] | Accuracy and reliability of open-source 3D printers compared to commercial systems. | Increasing utilization of open-source 3D printers in various fields. | Provides data to optimize printer settings for better accuracy. | Understanding geometric accuracy in open-source 3D printing. | Contributes significantly to understanding geometric accuracy in open-source 3D printing. | |
[39] | Challenges in applying advanced design strategies in AM and bridging the gap between design and manufacturing. | Integration of topology optimization and latticing strategies in AM. | Highlights the integration of CAD and AM through advanced design strategies. | Potential advancements in AM design and production. | Suggests potential advancements in AM design and production. | |
Innovative Approaches in CAD and AM | [40] | Potential of AM in sports equipment manufacturing, balancing rapid prototyping advantages against challenges of ensuring component reliability and performance. | Increased AM use in sports equipment and robotics. | Integration of CAD software and AM in developing functional prototypes. | Design optimization, cost reduction, and rapid prototyping. | Insights into AM in sports equipment production. |
[41] | Consensus on potential of topology optimization in AM and controversy regarding EBM’s cost and time effectiveness. | Employing advanced simulation techniques like topology optimization in additive manufacturing. | Practical application of topology optimization in EBM processes. | Significant advancements in lightweight and efficient design. | Implications for lightweight and efficient design in high-performance industries. | |
[42] | Effectiveness and practicality of automating the transition from topology optimization designs to manufacturable parts in AM. | Integration of topology optimization with automated product development for AM. | Potentially revolutionizes the development of optimized structures for AM. | Streamlines and improves product development efficiency. | Potential to significantly streamline and improve product development efficiency in AM. | |
[23] | Potential of hybrid manufacturing is acknowledged, with debate over its practicality and efficiency compared to established methods like SLM. | AM integration with robotic technologies and CAD/CAM for developing complex, high-quality components. | Demonstrates the integration of CAD/CAM with advanced manufacturing techniques. | Broader adoption of hybrid manufacturing methods in industrial applications. | Potential transformation of AM’s approach to component design and production. | |
Process Optimization and Quality Enhancement | [43] | Challenges in achieving high accuracy and consistent mechanical properties in 3D printed objects using fused deposition modeling. | Importance of optimizing process parameters in additive manufacturing. | Understanding the relationship between process parameters and product quality. | Improved quality and efficiency in AM processes. | Development of more efficient and accurate AM processes. |
[44] | Finding optimal process parameters for FDM and the varying approaches used in the field. | Growing importance of process optimization in FDM. | Significance of process parameter optimization in the AM workflow. | Better quality and efficiency in AM. | Suggests advancements in FDM process optimization | |
Use of AM in Diverse Industries | [45] | Trade-offs between conventional manufacturing methods and newer digital techniques regarding cost, flexibility, and design limitations. | Integrating advanced digital tools like 3D scanning and additive manufacturing in customizing bike frames. | Leads to more widespread adoption of digital prototyping techniques. | New possibilities for bike customization and innovation. | New possibilities for bike customization and innovation. |
[18] | Challenge in selecting appropriate CAD tools for topology optimization and the lack of standard assessment methods. | Growing integration of CAD tools in topology optimization for AM. | Highlights the need for practical CAD tools for AM processes. | Influences selection and development of CAD tools for optimized design in AM. | Suggests significant advancements in CAD tools for AM processes. | |
[46] | Consensus on AM’s potential for prototyping but skepticism about its viability for series production due to cost and technical limitations. | Growing recognition of AM’s potential beyond prototyping. | Highlights the gap between AM’s potential and its current application in series production. | Necessity for CAD tools and design methodologies better aligned with AM’s capabilities. | Emphasizes the need for practical DfAM knowledge. | |
Challenges in Adopting AM Techniques | [47] | Challenges in fully utilizing AM due to unique design and engineering implications. | Growing integration of AM in traditional manufacturing processes. | Provides a systematic approach for evaluating AM in early design. | Need for new design methodologies and integration within existing workflows. | Suggests a new approach for integrating AM in system design. |
[48] | Industry’s adaptation to AM techniques and challenges of integrating these new methods with traditional design principles. | Integration of AM in traditional manufacturing processes. | Proposes a method for integrating AM into traditional design processes. | Potential transformation in manufacturing and design strategies. | Suggests significant implications for manufacturing and design strategies. | |
Customer-Centric Design Approaches in AM | [49] | Integration of customer-centric approaches in manufacturing, balancing efficiency and user-friendliness. | Shift toward customer involvement in the AM design process. | Signifies a shift in CAD tools for AM, focusing on user-friendly, handheld interfaces. | Customization and user-centered design in AM. | Potentially transforms the AM industry through more customer-involved manufacturing processes. |
Optimization and Performance Enhancement in AM | [50] | Achieving precision and surface finish in AM for high-tech applications. | AM is used to create complex components for high-tech applications. | Emphasizes the importance of accurate CAD modeling and process parameter optimization. | Emphasizes the importance of accurate CAD modeling and process parameter optimization. | Highlights challenges and potential solutions in using AM for complex components. |
[51] | Challenges and potential solutions in using AM for producing components with complex internal structures for high-tech applications. | Developing specialized testing equipment for material characterization. | Effective use of CAD, FEA, and AM in developing testing equipment. | Effective use of CAD, FEA, and AM in developing testing equipment. | Demonstrates the integration of CAD, FEA, and AM in material testing. | |
[21] | Traditional methods versus kinematics-aware approaches in part decomposition for AM. | Integrating kinematics-aware approaches in AM for complex CAD parts. | A novel approach for part decomposition, emphasizing kinematics. | A novel approach for part decomposition, emphasizing kinematics. | Introduces a novel approach for part decomposition, emphasizing kinematics. | |
[16] | The potential of AM and topology optimization while acknowledging the standardization and implementation challenges. | Integration of advanced manufacturing techniques with computational design optimization. | A novel approach to product design that leverages CAD and AM strengths. | A novel approach to product design that leverages CAD and AM strengths. | Suggests significant implications for the design and manufacturing sectors. | |
[17] | Multifunctional optimization of mechanical systems using AM. | A trend toward using AM for optimized designs with multifunctional capabilities. | A new approach to multifunctional optimization in mechanical system design. | A new approach to multifunctional optimization in mechanical system design. | Provides a new approach to multifunctional optimization in mechanical systems. |
Framework Element | Contributions |
---|---|
Generative Design and Topology Optimization | Shift toward efficient design procedures, fostering innovation in AM [32]. |
Optimization of Material Properties and Structural Integrity | Emphasis on integrating material science and engineering principles into CAD/AM for enhanced performance and reliability [24]. |
Tailoring Applications to Specific Sectors | Customized strategies to meet industrial needs, enhancing acceptance and flexibility of CAD and AM applications [47]. |
Overcoming Barriers to Adoption | Tactics to address obstacles such as cost, standardization, and user-technology interfaces, enhancing adoption [34,46,49]. |
Customer-Centric Design and User Experience | Development of user-friendly CAD/AM tools responsive to customer inputs, improving design and manufacturing processes [16,46,47,49]. |
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Share and Cite
Vido, M.; de Oliveira Neto, G.C.; Lourenço, S.R.; Amorim, M.; Rodrigues, M.J.F. Computer-Aided Design and Additive Manufacturing for Automotive Prototypes: A Review. Appl. Sci. 2024, 14, 7155. https://doi.org/10.3390/app14167155
Vido M, de Oliveira Neto GC, Lourenço SR, Amorim M, Rodrigues MJF. Computer-Aided Design and Additive Manufacturing for Automotive Prototypes: A Review. Applied Sciences. 2024; 14(16):7155. https://doi.org/10.3390/app14167155
Chicago/Turabian StyleVido, Marcos, Geraldo Cardoso de Oliveira Neto, Sergio Ricardo Lourenço, Marlene Amorim, and Mário Jorge Ferreira Rodrigues. 2024. "Computer-Aided Design and Additive Manufacturing for Automotive Prototypes: A Review" Applied Sciences 14, no. 16: 7155. https://doi.org/10.3390/app14167155