Parts for Additive Manufacturing : Design Guidelines for the Defence Industry

Sammanfattning

Purpose – The purpose of this study was to assess the feasibility of integrating additivemanufacturing (AM) into an existing conventional manufacturing (CM) productionenvironment within a defence company, with focus on design considerations, sustainabilityaspects and operational implications. Methodology – This study was conducted by conducting a single-case study within a defencecompany setting. The data were collected through observations, document studies, semistructured interviews and validation through a workshop. Design Research Methodology(DRM) was applied in this study as a research design. Three phases were included in theresearch design process: Research clarification, descriptive study and a prescriptive study.Quantitative and qualitative methods were used to analyse findings in the study. Results – The findings suggest that AM is a flexible manufacturing process that can reducelead times, enable faster iteration cycles and support rapid design changes when appliedcorrectly. Design freedom is also emphasized as a key enabler of AM for innovative productsolutions. However, challenges in quality are still a concern along with design implications andprocesses. Analysis – A realization process consisting of guidelines for defining, screening, designing andevaluating long-lifecycle defence components using AM was developed based on findings fromthe study, where they were applied on a long-lifecycle defence component. The realizationprocess builds on DfAM and best practices, together with practical and sustainabilityimplications within AM. With emphasis on product quality, the guidelines are adapted to longlifecycle components to combat challenges in implementing AM in defence applications. Discussion – The study implicates that AM should be viewed as a strategic capability topromote flexibility and resilience. Designs are strongly dependent on AM process, materialselection and careful decision-making. Sustainability in AM is also highly contextual regardingeconomic and environmental aspects. Conclusions – AM shows great potential when applied for long-lifecycle defence componentswith emphasis on drivers such as shorter lead times, increased flexibility and faster productdevelopment cycles. It was found to be valuable for prototyping and spare part production,while also showing great potential for developing and manufacturing new components. AM canbe viewed as a strategic capability within the defence sector which supports productdevelopment and product lifecycle management. However, AM cannot replace CM methodssuch as IM, where it should be treated as a dual-sourcing method. AM can also contribute tosustainability improvements, depending on the application and implementation context.