Choice between virtual model and prototype in additive manufacturing design process

Abstract

Additive manufacturing (AM) enables the fabrication of complex shapes, which are sometimes impossible to get from conventional processes. In traditional design processes the performance of a part (such as mechanical strength) is evaluated by a numerical model (Finite Element computing) that is cheaper and quicker to obtain than a physical one. Today, when designing an AM dedicated object, it becomes easier to manufacture a physical part with exactly the same AM metallic process that will be used for the final serial part. Therefore, two options can be used to evaluate the performance of the part, a numerical model and a physical model. Then how to decide between the two options still causes confusion. The purpose of this research is to propose a method to help designers to make the best choice between numerical model and physical model for evaluating a part in a design process. To highlight the comparison between these options, our research methodology is based on the Design Research Methodology (DRM) model and several cases studies. The paper presents two case studies that lead to the proposal of a methodology and a list of criteria to help designers in comparing Virtual Model and Prototype in a given situation, and finally in deciding which option fits the best their needs in this context.