Virtual and Physical Prototyping

ISSN: 1745-2759 (Print) 1745-2767 (Online) Journal homepage: https://www.tandfonline.com/loi/nvpp20

Standardised product development for technology

integration of additive manufacturing

Johannes Rohde, Ulrich Jahnke, Christian Lindemann, Anne Kruse & Rainer
Koch

To cite this article: Johannes Rohde, Ulrich Jahnke, Christian Lindemann, Anne Kruse
& Rainer Koch (2019) Standardised product development for technology integration
of additive manufacturing, Virtual and Physical Prototyping, 14:2, 141-147, DOI:
10.1080/17452759.2018.1532801

To link to this article: https://doi.org/10.1080/17452759.2018.1532801

Published online: 15 Oct 2018.

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VIRTUAL AND PHYSICAL PROTOTYPING
2019, VOL. 14, NO. 2, 141–147
https://doi.org/10.1080/17452759.2018.1532801

Standardised product development for technology integration of additive

manufacturing
Johannes Rohdea,b, Ulrich Jahnkea,b, Christian Lindemannb, Anne Krusea,b and Rainer Kocha
a
Chair of Computer Application and Integration in Design and Planning (C.I.K.), Paderborn University, Paderborn, Germany; bDirect
Manufacturing Research Center (DMRC), The University of Paderborn, Paderborn, Germany

ABSTRACT ARTICLE HISTORY

The implementation of additive manufacturing (AM) as an industrial production process poses Received 1 October 2018
extraordinary challenges to companies due to the far-reaching differences to conventional Accepted 3 October 2018
processes. In addition, there are hardly any standards and guidelines or methodical process
KEYWORDS
models for the relatively new technologies that enable the reproducible and target-oriented use Additive manufacturing;
of AM. In order to solve this problem, five industrial companies together with the Paderborn product development
University are researching as part of the ‘OptiAMix’ research project funded by the Federal process; standards and
Ministry of Education and Research (BMBF). This paper focuses on the development of an ideal guidelines; technology
process chain. Reference processes of the OptiAMix partners were analysed, norms and integration
standards from conventional production were adapted and implemented and procedure models
developed OptiAMix were integrated. The resulting AM Product Development Process was then
applied and validated with the aid of a previously developed integration methodology using an
example component from the automotive industry.

Introduction and motivation and the development service provider EDAG Engineer-
ing, the consortium has high expertise in AM and is sup-
Additive manufacturing (AM) is on the threshold of
ported by INTES in the area of software development for
industrial application. On the one hand, this becomes
topology optimisation and WP Kemper as application
clear through the increasing use of technologies in
partner in the area of food technology. In order to
series production (e.g. mounting of the hood cover in
create a framework for the methods and tools developed
the BMW i8 Roadster (Krämer 2017)) and on the other
within the project and as a basis for integrating the tech-
hand through the focusing of research away from basic
nology into existing companies, an AM product develop-
and towards application research as current BMBF
ment process (AM-PDP) was developed within OptiAMix,
funding announcements show. However, SMEs in par-
which is described in detail below. In addition, an inte-
ticular lack the knowledge regarding the application of
gration methodology was developed for the implemen-
the technologies and the integration of the discontinu-
tation of this AM-PDP into company and thus for
ous AM production into a continuous line. Nevertheless,
integration of AM in general.
companies want and have to face the challenge if they
do not want to lose the technological edge. To enable
this integration, five industrial partners, coordinated by
AM in the context of conventional product
the Paderborn University, are researching since the
development
beginning of 2017 within the project ‘OptiAMix – Multi-
objective Optimised Product Development for Additive AM is still at the beginning of its industrial application.
Manufacturing’. As part of the BMBF’s ProMat_3D There are only a few standards and guidelines. In many
(BMBF 2017) funding program, the consortium is devel- respects, AM is also fundamentally different from con-
oping methods for integrating and applying the selective ventional manufacturing processes and a direct adap-
laser melting process and various tools to support the tation of an AM-PDP from conventional product
product development process. With the AM service pro- development processes is accordingly not possible. In
viders Krause DiMaTec, Hirschvogel Tech Solutions, the order to create a basis for an AM-PDP, the few existing
research institute DMRC of the Paderborn University standards and guidelines for AM must therefore be

CONTACT Johannes Rohde [email protected] Chair of Computer Application and Integration in Design and Planning (C.I.K.), Paderborn University,
Warburger Straße 100, Paderborn 33098, Germany; Direct Manufacturing Research Center (DMRC), The University of Paderborn, Warburger Straße 100, Paderborn
33098, Germany
© 2018 Informa UK Limited, trading as Taylor & Francis Group
142 J. ROHDE ET AL.

linked with individual adaptable standards of conven- create a solid basis for the AM-PDP, of which 10 rules
tional manufacturing. Figure 1 shows various standards are shown below as examples:
and guidelines in the chronological context of the
phases of product development. The most important
representatives are the VDI Guidelines 3405, the VDI (1) For process standardisation, it is necessary to define
2221 and the ISO 9000 series of standards. The VDI one or more specific product development pro-
Guidelines 3405 are the first guidelines in the German- cesses as reference processes (VDI 2221-2 2018).
speaking area addressing AM directly, the corresponding (2) Project reviews must be defined within the product
design guidelines, the manufacturing process and development (VDI 2221-1 2018).
related issues such as work safety. The VDI Guideline (3) The organisation has to maintain documented
2221 (‘Methodology for developing and designing tech- information in order to support the execution of
nical systems and products’) as a generally accepted its processes and to retain documented information
standard (Wulf 2002) defines the phase of product plan- (||ISO 9001 2015).
ning and development very precisely. Based on various (4) The organisation should monitor, analyse, evaluate
procedural models in the literature, this phase is and review the organisation’s performance (||ISO
divided into seven individual steps. This procedure 9004 2017).
applies to AM as to most other manufacturing technol- (5) During the design, cost control should be carried
ogies, since only the sequence is defined, but the out after each technical specification to ensure a
scope and depth remain explicitly in the employee’s short control loop (||VDI 2235 1987).
competence. In addition to VDI Guideline 2221, the ISO (6) A life cycle analysis should be realised in the early
9000 series defines quality management systems and design phases (||DIN 60300-3-3 2004).
task-independent standards that can also be applied to (7) The integrated component marking is rec-
the development of the AM-PDP. In contrast to VDI ommended to ensure traceability (||VDI 3405
2221, ISO 9000 and in particular the ISO 9001 and 9004 2013–18).
as parts of the series offer globally applicable rules (8) Together with the components, tensile test speci-
which can be applied to every process step and phase mens should be prepared in accordance with DIN
of the product development. From the standards and 50125 (|VDI 3405 2013–18).
guidelines mentioned above as well as the VDI guide- (9) For non-destructive testing of components, pen-
lines 2222 (‘Methodical development of solution prin- etration testing (DIN EN 571-1, DIN EN ISO 3452-1)
ciples’), 2235 (‘Economic decisions in design’) and 3600 and radiographic testing (X-ray regarding to DIN
(‘Processes and process orientation in production logis- EN 444 and CT regarding to DIN EN 13068-3) are
tics on the example of the automotive industry’) and recommended (VDI 3405 2013–18).
DIN 60300-3-3 (‘Dependability management – Part 3-3: (10) Used powder has to be collected to the highest
Application guide – Life cycle costing’) shown in possible extent and prepared for further use (VDI
Figure 1, a total of 33 rules have been extracted to 3405 2013–18).

Figure 1. Distribution of guidelines and standards to different phases of the AM-PDP.

 VIRTUAL AND PHYSICAL PROTOTYPING 143

New standardised product development guidelines (Figure 3). Rules that had previously not
process for AM been fulfilled were implemented by additional process
steps or compliance was ensured by adapting existing
The most important and decisive rule for the develop-
steps. This adaptation in the design phase addressed
ment of the AM-PDP is the setup and use of one or
in particular the adapted procedure model according
more reference processes for process standardisation
to VDI 2221 as well as the implementation of a continu-
as mentioned in (1). Within the framework of OptiAMix,
ous component documentation. In the final step, AM-
the existing processes of the network partners were
specific process steps and sequences were added to
documented, analysed and combined. Figure 2 shows
the AM-PDP (Figure 4). Here, attention was paid particu-
the process using the example of the design phase,
larly to areas that are still under development within the
built in adapted BPMN 2.0 (Business Process Modelling
OptiAMix research project and thus represent an exten-
and Notaton 2.0). BPMN 2.0 provides different elements
sion of the current state of research. At the beginning of
for the configuration of processes. These are events
the AM-PDP, the ‘Part Selection’ as well as the ‘Make or
(start and end of a process step), gateways (X, OR and
Buy’ decision was added. These two elements are
XOR decisions), activities (process steps) and docu-
especially considering the current state of technological
ments. In addition, optional, iterative and optional-itera-
readiness of AM as well as the lack of knowledge
tive activities were introduced in OptiAMix to reduce
(McCutcheon et al. 2014). Problems which developers
the number of junctions and to provide a clearer view
should solve methodically. For this purpose, methods
on the overall process. Following the development of
for strategic component selection (Kruse, Reiher, and
the reference process, it was evaluated regarding com-
Koch 2017) and a tool for investment evaluation of
pliance with the rules established by standards and

Figure 2. Reference process for the design phase of the AM-PDP.

144 J. ROHDE ET AL.

Figure 3. Design Phase of the AM-PDP with the implemented rules of standards and guidelines.

AM parts and components (Büsching 2018) were devel- related design of components (e.g. OptiStruct Altair as
oped at the Paderborn University. Since the costs of a shown on their website). The OptiAMix consortium
component strongly depend on its build time and and especially the software developer INTES wants to
therefore on its volume, the manufacturing height and expand this and additionally enable cost, post-proces-
consequently also on the build job height (Gibson, sing and production-related optimisation. For this
Rosen, and Stucker 2010), various process steps of the purpose, design guidelines for the corresponding
AM-PDP, such as the determination of the build direc- targets are developed at the Paderborn University, con-
tion, imply an increased cost responsibility. Due to this verted into a machine-readable format and
step-by-step cost development during several process implemented by INTES in their software Permas in
steps and as a logical consequence of the ‘Make or order to create a sustainable optimiser (Tominski and
Buy’ decision, a ‘Continuous Cost Management’ was Lammers 2018; Fischer, Wulf, and Wang 2018). In
added to the process based on the continuous com- addition to Part Selection and Make or Buy decisions,
ponent documentation (Lindemann 2018). The third Continuous Cost Management and Multi-objective
new element is the ‘Multi-objective Optimisation’ of Optimisation, the process steps of ‘Part Marking’ were
components and thus the core topic of the OptiAMix added to the design phase of the AM-PDP. The VDI
research project. Previous solutions for component 3405 also recommends the identification of parts to
and topology optimisation only provide the load- be produced as additives as a decisive bundle of
 VIRTUAL AND PHYSICAL PROTOTYPING 145

Figure 4. Design Phase of the AM-PDP with the implemented AM-specific process steps.

activities in order to achieve traceability and to link digital product data (Jahnke, Bornefeld, and Koch
physical parts with their digital twin and the digital 2016). A solution to mark products individually for AM
process chain, for example, secured by blockchain tech- is highly desired by industry. Using established CAD
nologies. This connection is often mentioned as one software tools a marking for traceability can be inte-
fundamental requirement to reach the objectives of grated manually. Doing the same for a whole batch of
Industry 4.0, the next industrial revolution (Reeves and products that need an individual marking, the effort is
Mendis 2015). AM as a technology with high relevance not reasonable in relation to the achievable benefits.
in the scope of Industry 4.0 offers the potential to Therefore a software-driven solution has been devel-
directly produce markings for traceability during the oped by Additive Marking, a spin-off of Paderborn Uni-
manufacturing process. Even industries that are not versity, to allow efficient integration of markings in the
focusing on products with critical functionality can digital product also for high batch production (Jahnke
benefit from markings for quality management and liab- 2018).
ility exclusion. The identifiability of products is a valu-
able outcome. Markings can be understood as a kind
Application and discussion
of individualisation of parts. As individualisation does
not increase production costs when using AM the only The potential of the AM-PDP and AM-specific methods
effort results from the integration of markings in the could already be demonstrated by a practical example
146 J. ROHDE ET AL.

Figure 5. Car Door Hinge by EDAG Engineering.

introduced into the project by EDAG Engineering. As a Funding

result of the strategic part selection carried out at
This research and development project is funded by the
EDAG, the car door hinge shown in Figure 5 was selected. German Federal Ministry of Education and Research (BMBF)
As a visible structural component, it offers high potential within the program ‘Innovations for Tomorrow’s Production,
for load-compliant optimisation and, at the same time, Services, and Work” (funding number 02P158131) and
represents an enthusiasm feature due to its identifiability managed by the Project Management Agency Karlsruhe (PTKA).
as an AM part during the opening process of the door,
which permits increased costs compared to conventional
manufacturing. In the course of the development, a
Notes on contributors
weight reduction of 51% was achieved by the optimis- Johannes Rohde, M.Sc. has been working as a research assistant
ation, which was, however, still carried out using estab- at the University of Paderborn in the field of ‘Computer Appli-
cation and Integration in Design and Planning’ since 2015. Prior
lished optimisation software. This will be repeated by
to this, he worked as a student assistant at the Direct Manufac-
INTES following completion of the development of the turing Research Center (DMRC) for almost four years during his
multi-target optimiser, but is already expected to lead studies in mechanical engineering, specializing in plastics tech-
to further improvements in terms of multi-target optim- nology. Since the beginning of 2017, he is coordinating the
isation (post-processing and production-oriented BMBF research project ‘OptiAMix - Multi-target Optimized
implementation). In addition, the developed pro- Product Development in Additive Manufacturing’. His research
aims at the integration of additive manufacturing into existing
duction-integrated part marking has already been
companies and their business processes.
implemented in the component. This ensures both trace-
Dipl.-Ing. Ulrich Jahnke started his academic career as a
ability along the entire AM-PDP and product protection in
Research Assistant at the Direct Manufacturing Research
the event of recourse claims through invisible markings. Center, Paderborn University. Ulrich’s work focuses on
process analysis and optimization to prevent product piracy
Acknowledgements when using additive manufacturing. His research aims to
achieve a holistic view on the cost-efficient application of AM
The research leading to this results was carried out in the during the product lifecycle. In 2017, Ulrich co-founded Addi-
project OptiAMix – ‘Multi-target-optimised and continuously tive Marking to offer software-driven marking for AM parts,
automated product development for additive manufacturing allowing traceability of industrial applications.
in the product development process’. The author is responsible
for the contents of this publication. Dr.-Ing. Christian Lindemann has studied industrial engineering
at the University of Paderborn with a focus on strategic pro-
duction and innovation management. Afterwards, he joined
the chair for ‘Computer Application and Integration in Design
Disclosure statement
and Planning’ as scientific staff from Prof. Dr.-Ing. Rainer Koch.
No potential conflict of interest was reported by the authors. Since 2010 he is strongly involved in the Direct Manufacturing
 VIRTUAL AND PHYSICAL PROTOTYPING 147

Research Center (DMRC) at the University of Paderborn. One of Büsching, J. 2018. “Prozessbezogenes Anlaufmanagement in
his main research topics is the cost structure of Additive Manu- der additiven Fertigung.” Paper presented at the 4th 3D
facturing during the product lifecycle with the aim to increase printing: Additive Manufacturing in Automotive Industry,
the number of part candidates for the AM technology. Mr Linde- April 11-12, in Bamberg, Germany.
mann finished his Ph.D. thesis with the topic ‘Cost-Efficient DIN 60300-3-3. 2004. Dependability Management – Part 3.3:
Design and Planning for Additive Manufacturing’ in 2017. Application Guide – Life Cycle Costing.
During his research, he has participated in industry and EU- Fischer, R., C. Wulf, and T. Y. Wang. 2018. “Efficient Design
FP7 Framework projects as well as in projects of the European Creation and Validation.” Paper presented at the Permas
Space Agency (ESA). He is active in many AM networks and users’ conference, Stuttgart, Germany.
AM standardization activities. Following his time as scientific Gibson, I., D. W. Rosen, and B. Stucker. 2010. Additive
staff at the DMRC, he was Research & Exploitation Manager Manufacturing Technologies – Rapid Prototyping to Direct
before becoming the Managing Director of the DMRC. He is Digital Manufacturing. New York: Springer Verlag.
active in the fields of education in additive manufacturing in ISO 9001. 2015. Quality Management systems – Requirements.
industry seminars and at the University of Paderborn. ISO 9004. 2017. Quality management - Quality of an organis-
Anne Kruse, M.Sc has studied Mechanical Engineering at the ation - Guidance to achieve sustained success.
Karlsruhe Institute of Technology with a focus on production Jahnke, U. 2018. Wer hat’s gedruckt. Magazin für
management and logistics. She has received her Master Nanatechnologie, 01-2018, Neue Werkstoffe und Photonik.
Degree in 2015. Since then, she works as a member of the scien- Jahnke, U., P. A. Bornefeld, and R. Koch. 2016. Production-inte-
tific staff at the chair for Computer Application in Design and grated Markings for Traceability of AM Parts in the Context
Planning in cooperation with the Direct Manufacturing Research of Industry 4.0. Austin: 27th Annual International Solid
Center (DMRC) at Paderborn University. One of her main Freeform Fabrication Symposium Proceedings.
research topics is the cost analysis of additive manufactured pro- Krämer, A. 2017. Neuer BMW i8 Roadster enthält mit Metallteil
ducts. During her research, she has participated in the EU-H2020 aus dem 3D-Drucker und spart 40 Prozent Gewicht. 3D-gren-
project ‘iBUS – an integrated business model for customer zenlos Magazin, https://www.3d-grenzenlos.de/magazin/3d-
driven custom product supply chains’ as well as in the project objekte/bmw-i8-roadstar-teil-aus-3d-drucker-27330013/
of the European Space Agency (ESA) ‘NewStructure – Direct (accessed September 26, 2018).
Manufacturing of Space Hardware for NGP’. Since 2017, she par- Kruse, A., T. Reiher, and R. Koch. 2017. Integrating AM into exist-
ticipates in the BMBF funded project ‘OptiAMix – Multi-objective ing companies - selection of existing parts for increase of
Optimised Product Development for Additive Manufacturing’, acceptance. Austin: 28th Annual International Solid
with the main research field ‘part selection for AM’. Freeform Fabrication Symposium Proceedings.
Lindemann, C.-F. 2018. Systematic Approach for Cost Efficient
Prof. Dr.-Ing. Rainer Koch received his Dr.-Ing. (Ph.D.) RWTH Design and Planning with Additive Manufacturing. Aachen:
Aachen in 1985. From 1985 to 1989 he was Senior Consultant Shaker Verlag.
and Head of CAD/CAM Department in a German software McCutcheon, R., R. Pethick, B. Bono, M. Thut, J. McNelly, G.
company. Since 1989 he is full Professor at the University Pader- Carrick, C. Sulavik, M. Portnoy, and T. Waller. 2014. 3D
born, Faculty of Mechanical Engineering, Research Group ‘Com- Printing and the New Shape of Industrial Manufacturing.
puter Application and Integration in Design and Planning’ New York.
(C.I.K.). The research areas are Computer Aided Design, Reeves, P., and D. Mendis. 2015. The Current Status and
Quality Management and Information Management. Current Impact of 3D Printing Within the Industrial Sector: An
application areas are Additive Manufacturing and Public Analysis of Six Case Studies. Newport: The Intellectual
Safety and Security. In this context, more than 30 national Property Office.
and European funded research projects have been and are con- Tominski, J., and S. Lammers. 2018. “Software-assisted Design
ducted and coordinated. Rainer Koch is a volunteer fire officer Check for Additive Manufactured Components.” Paper pre-
and since more than 40 years member of the Fire Department sented at the Permas users’ conference, Stuttgart, Germany.
Dortmund. Additionally, he is appointed technical consultant VDI 2221-1. 2018. VDI-Guideline 2221 Part 1: Development of
for the Dortmund Fire Department and Deputy Head of IFR Technical Products and Systems - Design of Individual
(Institute for Firefighting and Rescue Technology), the research Product Development Processes. Düsseldorf: VDI Verlag.
division of Dortmund Fire Department. Additionally Prof. Dr.- VDI 2221-2. 2018. VDI-Guideline 2221 Part 2: Development of
Ing. Rainer Koch acts as convenor of Working Group 3 ‘Emer- Technical Products and Systems - Model of Product
gency Management’ of ‘ISO/TC 292 Security and Resilience’ Development. Düsseldorf: VDI Verlag.
and is member of the European mirror committees. VDI 2235. 1987. VDI-Guideline 2235: Economic Design Decisions.
Düsseldorf: VDI Verlag.
VDI 3405. 2013–18. VDI Guideline 3405: Additive Manufacturing
Processes, Rapid Manufacturing. 13 vols. Düsseldorf: VDI
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