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Additive manufacturing gives new freedom to part design by enabling the manufacturing of complex structures. Mastering this degree of freedom poses challenges for product developers with experience from conventional manufacturing. In order to meet this challenge in a structured manner, a practical method is presented in which creative idea development is combined with software-based design optimization. First, optimization goals are defined. Then a baseline design is developed through a creative ideation process. Variants are derived from the baseline design, evaluated according to simulation results and selected. The method is illustrated by the development of a lightweight and function-integrated gear wheel. [ABSTRACT FROM AUTHOR] more...

The decision for choosing a manufacturing technology for a specific product is primarily based on cost in industrial practise. Current government regulations together with international projects like the Convention on Climate Change introduce further factors targeting a sustainably choice of manufacturing sequences. A typical measure is total energy embedded in a product based on the employed manufacturing route. Hence, industrial decision makers may have to assess both a cost- and energy-efficient production sequence. This results in the main challenge of an early estimation of manufacturing costs and energy consumption for choosing the most suitable production scenario. This is a crucial point to an industrial implementation of additive manufacturing (AM) and specifically for expensive and energy-intensive technologies for industrial metal processing like laser beam melting (LBM). This includes a consideration of both the entire process sequence embedded in a suitable production scenario and potential for product redesign derived from the use of LBM. This paper suggests two integrated models for cost and life cycle assessment in a cradle-to-gate framework focussing an industrial process sequence. Gear wheel manufacturing in a low volume or high variant production scale is chosen as a production scenario. Three industrial process sequences for gear production based on machining, hobbing, and LBM are investigated. Special focus is set to the impact of lightweight design on energy- and cost-efficiency of the manufacturing sequence. The key factors influencing cost- and energy-intensity are identified recommending a production scenario that is worthwhile for LBM for the small scale production of gears. It is concluded that both cost- and energy-efficiency have to be assessed with different process alternatives in order to identify a worthwhile scenario for LBM based on cost and life cycle assessment models. Lightweight design is identified as the most significant factor for reducing costs and energy-consumption that suggests employing lightweight design for cost- and energy-efficiency. The intended audience of this contribution are scientists, industrial applicants of LBM and conventional gear manufacturers. [ABSTRACT FROM AUTHOR] more...