What do a dough cutting knife, a brake caliper and a cubesat propellant tank have in common? They have all been selected by Additive Industries as finalists in its Additive World Design for Additive Manufacturing Challenge 2019. Along with three other projects, the finalists were selected from a total pool of 121 entries.
Industrial 3D printing company Additive Industries launched the Design for Additive Manufacturing Challenge at Dutch Design Week in October 2018, when it invited professionals and students to submit innovative part redesigns that leveraged additive manufacturing to its contest. Now, the top three student and top three professional submissions have been chosen to move into the final round of the challenge.
“The redesigns submitted from all over the world and across different fields like automotive, aerospace, medical, tooling and high tech, demonstrated how product designs can be improved when the freedom of additive manufacturing is applied,” said Daan Kersten, CEO of Additive Industries. “This year again we saw major focus on the elimination of conventional manufacturing difficulties, minimization of assembly and lowering logistical costs. There are also interesting potential business cases within both categories.”
The professional finalists
In the professional category, submissions from UK-based Carbon Performance Limited, Netherlands-based K3D and India-based Wipro3D were chosen to move through into the finals. Carbon Performance Limited’s proposal, submitted by Revannth Narmatha Murugesan, is a redesign of a hyper-performance suspension upright, a critical load bearing component in sports cars. With additive manufacturing and topology optimization, the part’s weight could be reduced by 30%.
Jaap Bulsink from K3D proposed a redesign of a cutting dough knife, an attachment operated by a robot to—as the name suggests—cut dough. The clever redesign leveraged AM to reduce weight by up to 90% and reduce production costs. Not only that, the 3D printed design also solves such problems as dough stickiness and uneven cut depths in its design.
The last entry from the professional category to be selected as a finalist was submitted by Kartheek Raghu from Wipro3D and consists of a 3D printed Cold Finger thermal trap for the sublimation process. The device, which integrates a fine lattice structure, holds cryogenic temperature for longer than its traditionally manufactured counterpart, improving how tht device condenses all vapours, except permanent gases, into a liquid or solid.
There were also two honourable mentions in the professional category: a unibody hydraulic system submitted by last year’s challenge winners, Aidro Hydraulics & 3D Printing; and the Contirod-Düse, proposed by Nina Uppenkam from Germany’s SMS Group. In the latter design, the conventional CONTIROD Nozzle was consolidated into a single part and saw significant weight reduction.
The student finalists
In the student category, the finalists came from the Nanyang Technological University in Singapore, McMaster University in Canada and the Landmark University in Nigeria. The first of the three, submitted by a two-student team, is a 3D printed brake caliper, whose design was optimized to reduce the weight by 35%.
Abraham Mathew from McMaster University used topography optimization to improve the design and stiffness of a cubesat propellant tank. This was achieved by modifying surface features without having to increase wall thickness or mass.
Last, Obasogie Okpamen from Nigeria’s Landmark University demonstrated how topology optimization and 3D printing could be leveraged to achieve mass and material reduction for a twin spark connecting rod.
The winners of the 2019 Design for Additive Manufacturing Challenge will be announced in March at the Additive World Conference Award Dinner in Eindhoven.