User-Centered design in U.S Air force additive manufacturing; case studies on tools, jigs, and topology optimization

Abstract

User-centered Additive Manufacturing (AM) design processes were applied to tools and jigs used in operational tasks for various career fields. Case study analysis was used to investigate to what degree can user centered AM design processes and topology optimization be utilized by various Air Force squadrons in everyday and contingency operations and to what degree topology optimization can be applied to the tools and jigs developed while preserving user requirements. Nine case studies evaluated tools and jigs for Explosive Ordnance Disposal and the Engineering Management Laboratory at the US Air Force Institute of Technology. If deemed appropriate by the customer and designer, topology optimization was applied. Surveys were used to rate different aspects of usability for each case study and the results were used to identify trends between the case studies. Overall, this research found that AM and topology optimization could be applied to both daily and contingency operations.