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Procedia CIRP 00 (2018) 000–000
ScienceDirect
Procedia CIRP 00 (2018) 000–000 www.elsevier.com/locate/procedia
Procedia CIRP 00 (2017) 000–000 www.elsevier.com/locate/procedia
Procedia CIRP 79 (2019) 107–112
www.elsevier.com/locate/procedia

12th
12thCIRP
CIRPConference
Conferenceon
onIntelligent
IntelligentComputation
ComputationininManufacturing
ManufacturingEngineering,
Engineering,18-20
CIRPJuly
ICME2018,
'18
12th CIRP Conference on Intelligent Computation in Manufacturing
Gulf of Naples, Italy Engineering, CIRP ICME '18
Incremental Manufacturing:
28th CIRP Design Model-based
Conference, Maypart2018,design and process planning
Nantes, France
Incremental Manufacturing: Model-based part design and process planning
for Hybrid Manufacturing of multi-material parts
A new methodology
for Hybrid to analyze the functional
Manufacturing and physical
of multi-material architecture of
parts
existingReichler
Ann-Kathrin products for an assembly oriented product family identification
a, *, Roman Gerbersa, Paul Falkenbergb, Eiko Türkb, Franz Dietricha, Thomas Vietor b,
Ann-Kathrin Reichler *, Roman Gerbers , Paul
a, a Falkenberg
Klaus Drödera, Eiko Türk , Franz Dietrich , Thomas Vietor ,
b b a b
a
a Paul Stief *, Jean-YvesKlaus Dröder
Dantan, Alain Etienne, Ali Siadat
Institute of Machine Tools and Production Technology, Langer Kamp 19 b, Braunschweig, 38106, Germany
ofInstitut for Tools
Engineering Design, Langer Kamp Langer
8, 38106, Braunschweig,
4 Rue38106, Germany
b
a
École Nationale Institute
Supérieure Machine
d’Arts and Production
et Métiers, Arts Technology,
et Métiers ParisTech, LCFCKamp
EA 19 b, Braunschweig,
4495, Augustin 38106, Germany
Fresnel, Metz 57078, France
b
Institut for Engineering Design, Langer Kamp 8, 38106, Braunschweig, 38106, Germany
* Corresponding author. Tel.: +49-531-391-7691; fax: +49-531-391-7691. E-mail address: a-k.reichler@tu-braunschweig.de
**Corresponding
Correspondingauthor.
author.Tel.:
Tel.:+33
+49-531-391-7691; fax: +49-531-391-7691.
3 87 37 54 30; E-mail E-mail address: a-k.reichler@tu-braunschweig.de
address: paul.stief@ensam.eu

Abstract
Abstract
Abstract
Incremental Manufacturing is a hybrid-manufacturing concept where standardized base workpieces are made in large volume
Incremental
production
In Manufacturing
first
today’s business and finalized
environment, isthe
a hybrid-manufacturing
by additive
trend manufacturing.
towards more productconcept where
The concept
variety standardized
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for product-specific
unbroken. Due to this mademolds
in large andvolume
the tools,
need of
production
enabling
agile first and finalized
a multi-scale
and reconfigurable production
production bysystems
additive manufacturing.
- the flexibility
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cope withThe
scale concept
product
various reduces
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products and the need
sizes
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product-specific
asfamilies.
well Toproduction molds This
design andvolume.
optimize and tools,
paper
production
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presentsasanmulti-scale
approach toproduction
as to choose reduce the- arising
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complexity
matches, fromproduct
product the new
analysisvariants
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methods are sizes
freedom as Indeed,
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analyze an design
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phase.
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Different new design
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to largely
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multi-dimensional
terms number and
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nature designprocess
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of components. phase. For impedes
This during
fact this
themanufacturing,
design ofmaterial
phase comparison
an efficient and
and process
multi-material partsofmodels
choice for will be
Incremental
appropriate merged to support
Manufacturing.
product family the multi-dimensional
combinations for the production
decision-making
© 2018AThe
system. Authors.
new process during
Published
methodology the design
by Elsevier
is proposed B.V.phase
to analyze of multi-material
existing products in viewparts for Incremental
of their Manufacturing.
functional and physical architecture. The aim is to cluster
Peer-review
these
© products
© 2018
2019 The under responsibility
in new
The Authors.
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Published of Elsevier
by
by the scientific
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Elsevier committee
B.V.families
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for the 12th CIRPof
optimization Conference on Intelligent
existing assembly Computation
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future reconfigurable
Engineering.
Peer-review
assembly under
systems. responsibility
Based on of
Datum the
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of the Conference
products is on Intelligent
analyzed. Computation
Functional in Manufacturing
subassemblies
Peer-review under responsibility of the scientific committee of the 12th CIRP Conference on Intelligent Computation in Manufacturing are identified, and
Engineering.
aEngineering.
functional analysis is performed. Moreover, a hybrid functional and physical architecture graph (HyFPAG) is the output which depicts the
Keywords:
similarity Additive
between manufacturing;
product Hybrid
families by machining;
providing designComputer automated
support to process planning
both, production system planners and product designers. An illustrative
Keywords:
example of aAdditive manufacturing;
nail-clipper Hybridthe
is used to explain machining;
proposed Computer automated
methodology. processcase
An industrial planning
study on two product families of steering columns of
thyssenkrupp Presta France is then carried out to give a first industrial evaluation of the proposed approach.
© 2017 The Authors. Published by Elsevier B.V.
Peer-review under responsibility of the scientific committee of the 28th CIRP Design Conference 2018.
1. Introduction concepts should lead to a significant reduction in variant-
1. Introduction
Keywords: Assembly; Design method; Family identification concepts should lead
specific expenses to a significant
compared reduction
to traditional in variant-
form-bounded
1.1 Initial position specific expenses compared to traditional
processes while maintaining sufficient production capacity. form-bounded
1.1 Initial position processes
To tackle while maintaining
this problem sufficient
the authors production
propose capacity.
the production
An economic variation of products is a necessity, which is To tackle this problem the authors propose
concept called “Incremental Manufacturing”, which faces the the production
1.derived
Introduction
An economic
from thevariation
costs-, ofmaterial-
products or is agenerally
necessity,resource-
which is of the product
concept
cost-efficient range
calledproductionandofcharacteristics
“Incremental Manufacturing”,
variant flexible manufactured
which
parts and/or
faces
[1, 2]. the
derived from the costs-, material- or
efficient implementation of the product and value-addedgenerally resource- assembled in this
cost-efficient system. of
production In variant
this context,
flexibletheparts
main[1,challenge
2]. in
Due toimplementation
efficient
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market. in
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and domain
value-added
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communication
diversity and
demanded an
by ongoing
the trend
market.
technical-functional differentiation of products and of
The digitization
drivers are and
the products, a limited
1.2 Incremental product range or existing product families,
Manufacturing
digitalization,
fulfillment ofmanufacturing
technical-functional enterprises
differentiation
customer-specific of are facing
products
requirements. important
and the
Form-bound but In
alsoorder
to be able to
to enableanalyze and to compare
a multi-scale products with
production to definethe
challenges
fulfillment in
of today’s market
customer-specific environments:
requirements.
processes such as injection molding or aluminum die-cast are a continuing
Form-bound new Inproduct
order families.
to enable It can
a be observed
multi-scale
flexibility to scale product variants and that classical
production existing
with
volume, thea
tendency
used for towards
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molding
large development
seriesorproduction.
aluminum die-cast times
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flexibility areproduct
to scale
called regrouped
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variants of clients
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proposed
shortened
used for product lifecycles.
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series there
production.
customer demand for individualization and technical is an increasing
The rising However,
which combines additive manufacturing processes withto other
concept assembly
called oriented
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(IM)hardly
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demand at thenumber
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a global
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2212-8271 © system,
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Authors. Publishedtobyhave a precise
Elsevier B.V. knowledge comparison of different product families. Addressing this
Peer-review
2212-8271 ©under
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The Authors. of the scientific
Published committee
by Elsevier B.V.of the 11th CIRP Conference on Intelligent Computation in Manufacturing Engineering.
Peer-review under responsibility of the scientific committee of the 11th CIRP Conference on Intelligent Computation in Manufacturing Engineering.
2212-8271©©2017
2212-8271 2019The
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Peer-reviewunder
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10.1016/j.procir.2019.02.020
108 Ann-Kathrin Reichler et al. / Procedia CIRP 79 (2019) 107–112
A. Reichler et al. / Procedia CIRP 00 (2018) 000–000
allows scalability towards series production of customized
multi-material products.
This production concept offers a high degree of freedom in
the domains of product design, production sequence as well as
the interaction and influence of different incremental
production steps. Figure 1 shows a comparison of a standard
hinged pillar (aluminum die-casting) and an IM design
variant. IM allows, for example, a flexible combination of
material and manufacturing technologies so that the number of
possible production variants increases enormously. This high
degree of freedom must be handled by interlinking the various
dimensions of product design and production in an early
design phase in order to implement the concept of IM
efficiently. For this reason, the two domains design
technology and manufacturing process technology have to be
integrated. This integration leads to a product design that is on
the one hand optimized in terms of e.g. weight and functional
integration and on the other hand optimized for cost-efficient
manufacturability of components with many variants. The
integral consideration of these two domains is, therefore, a
crucial requirement for IM.
Fig. 1. Hinged pillar conventional manufacturing (left) and different
incremental manufacturing variants (right)
This paper presents a theoretical approach for an integrated
part design during the product design phase to cope with the
high degree of freedom rising from the new production
concept of IM during the product design phase. The
theoretical functionality of the method is demonstrated in a
case study for a hinged pillar, the results are discussed,
lessons learned are stated and an outlook for future research is
given.
2. Literature Review of Design methods and Process
planning tools for incremental manufacturing
This section presents a literature review of current research on
design and process planning methods in the context of
additive and hybrid additive manufacturing. Since IM is an
enlargement of the hybrid additive manufacturing concepts
current methods and approaches can be used as a basis to
further develop a design and process planning method for IM.
2.1. Design and product architecture for additive/ hybrid
additive manufacturing
The aforementioned increase in complexity in the design
freedom of incrementally manufactured parts can partly be
countered by familiar methodological approaches such as
Design for Additive Manufacturing (DFAM) [3, 4] or
topology optimization. The topology optimization of
components uses the potential of additive manufacturing to
develop structures with minimum weight and simultaneous
maximum mechanical rigidity [5].
It should be noted that segmentation will play an important
role in the design of parts for IM because the production
concept offers the possibility to combine an unlimited number
of potential processes. Ponche developed a holistic approach
for the DFAM, where not only the costs and weight of the
products are considered, but also the design and
manufacturing requirements [6]. Ranja et al. developed an
approach for design guidelines that addressed the
manufacturability of the components. The designer receives
information about disturbing geometries that influence the
manufacturability of the component at the same time, an
attempt is being made to reduce the cost of the component [7].
The description forms and the methods for evaluation of
manufacturability from the state of the art, can be used as
basis to develop a design and product architecture for IM.
However, current approaches are focused on monolithic
materials and must therefore be adapted and extended for
example by aspects of semi-finished products.
In order to increase the flexibility of the current
monolithic process design for additive manufacturing, the
design must include a corresponding freedom in process
planning. Kerbrat presents such a design for manufacturing
(DFM) approach, in which feature recognition is used to
automatically subdivides a component geometry into
component regions to be produced by additive or subtractive
manufacturing [8]. Homar proposes a processing time- and
cost-oriented algorithm to reduce the portion of the
component that has to be manufactured additively in order to
increase the productivity [9]. Joshi presents a similar approach
where a complexity number is used to divide the component
into additive, subtractive and hybrid areas [10]. For IM such
approaches have to be extended in such a way, that semi-
finished parts can be considered.
It can be concluded from the state of the art in design
methodology that there are already methods available to
design additive manufactured components with monolithic
material designs and to design simple additive-subtractive
production routes. In summary, the following research
demand has to be addressed to develop methods for Design
for IM.
• First, further description forms and design methods are
necessary for production-oriented and load-path adapted
integration of semi-finished products into the product
 Ann-Kathrin Reichler et al. / Procedia CIRP 79 (2019) 107–112
A. Reichler et al. / Procedia CIRP 00 (2018) 000–000
design, which will make the monolithic material
composition more flexible.
• Second, methods for assigning suitable production routes
(sequence of production processes) are required that can
ideally identify production routes that can be processed
automatically in a future production system.
An integrated methodology that incorporates these two
research demands is proposed in this paper.
2.2. Process planning for additive & hybrid additive
manufacturing
In the field of additive manufacturing, the term production
planning refers to the definition of component alignment, the
arrangement of support structures, the slicing of components
and the generation of tool paths [11, 12]. In addition, the
integration of measurement technology and the acquisition of
current process values are considered as relevant areas of
activity for processes planning [13]. In case of additive
manufacturing production planning can be reduced to a pure
technological production planning which is carried out
isolated for each of the individual steps (additive production,
post-processing). Some of these methods can be adapted for
IM, for example slicing and tool path generation, but the
aspect of using semi-finished products as a base part is not
mentioned yet.
For hybrid additive manufacturing the influences of
processes on subsequent processes are also taken into account.
This results in an extension of the process planning method,
which also includes the determination of the additive-
subtractive process sequence in hybrid additive manufacturing
[14]. A proposal for the process combination of fused
deposition modelling (FDM), machining post-processing and
measuring steps is made in the method "iAtractiv". The
method is based on a computer algorithm to determine the
sequence of the individual processing steps [15]. Production
sequence planning is important for hybrid additive
manufacturing but for IM it plays an even greater role due to
the variety of materials and production processes that can be
used and the higher number potential production increments.
The planning of production routes for hybrid additive
manufacturing must also consider geometric decomposition
and the kinematic accessibility. The work in the field of the
additive laser application process can be used to break down a
part into sub-parts followed by determination of the assembly
sequence to guarantee the manufacturability of the sub-parts
[16, 17]. Also Kao's work shows that the decomposition of a
component into manufactural subassemblies is an essential
part of process planning for hybrid additive manufacturing
[18, 19]. These approaches can be adapted for IM by
integrating further production processes.
Beyond the geometric disassembly, the use of an existing
component plays an important role to build up a new part by
combining additive and subtractive technologies [20]. This
decision to use an existing structure comparable to a semi-
finished product is also made within the scope of process
planning and can be transferred to the concept of IM.
From the state of research, the following research demand
for IM arises.
109
• First, existing planning approaches for determining the
production sequence must be supplemented by taking into
account the influence of the downstream production step.
• Second, the description of the component segments must
be extended to store manufacturing knowledge so that this
can be used during sequence planning.
• Third, the results from the production route planning must
be used as feedback for the design phase in order to adapt
the design of the components in such a way that shorter
assembly times or lower costs of the end product result.
These research demands have to be addressed for the future
establishment of IM.
3. Actual problems/action requirements
The combination of additive manufacturing steps with
prefabricated semi-finished parts increases the decision-
making freedom in component design and production
planning. However, the component design specifications have
a more restrictive effect on the production route than
established component concepts. This means that the
incremental production route must be included early and even
more informatively in the component design definition. This
combinatorial complexity is addressed in this paper in order to
contribute to the methodical design control of IM.
The need for research includes the combination of
manufacturing and design methods and the integration of pre-
products into an optimized production chain consisting of a
combination of different additive and subtractive production
as well as joining/ assembly steps.
4. Proposal approach for Design and Process planning for
Incremental Manufacturing
4.1. Research objective
The objective of this paper is the development of a method
that enables an integrated design of parts and variant-flexible
planning of production routes according to the basic
principles of IM. The method is derived from the ambition to
control the high degree of freedom that results from the
combination of additive manufacturing processes with semi-
finished product-oriented part concept of IM.
4.2. Approach for Design and Processes planning
The proposed method is based on a combined segmented
approach, where the part is first dived in monolithic segments,
and then the segments are optimized and evaluated based on
functional and constructive aspects. Based on the
segmentation and a step-by-step concretization, a tree-like
structure is created. The approach is based on a prioritization
and an early elimination of variants by plausibility rules and
model-based function and production parameters. Figure 2
shows a proposed procedure model for an integrated part
design for IM.
110 Ann-Kathrin Reichler et al. / Procedia CIRP 79 (2019) 107–112
A. Reichler et al. / Procedia CIRP 00 (2018) 000–000
Fig. 2. Procedure model for the integrated component design for IM
The procedure is divided into two main steps “combined
generation of a part topology” and “combined generation of a
production sequence and multi criteria evaluation”. These two
steps are executed alternatingly and the results are used as
feedback for the next iteration.
The first step includes the segmentation of an already
existing part into sub parts called part segments. The
segments are assigned to materials and processes and
afterwards the segments are dimensioned and function
optimized. This results in the "list of priorities
(functionality)", which lists the combinatorial component
candidates according to functional aspects. These prioritized
segments are then transferred to the second step “combined
generation of a production sequence and multi-criteria
evaluation”. Based on the combinatorial freedom different
production routes are generated for the component candidates.
For each of these candidates, the complexity is evaluated and
the "list of priorities (production technology)" is drawn up
according to production-technical aspects. These results are
used as feedback for the first step for refinement and re-
execution.
A system and access architecture has to be build up to
realize the proposed model for integrated component design
for IM (see figure 3). The initial point is the central sequence
control, which calls up the functionalities and manages the
data and communication channels that arise. This proposed
architecture enables, on the one hand, a separate storage and
management of the relevant construction and production
functionalities and on the other hand, it is possible to realize a
close linking via the commonly used data structure “part and
Fig. 3. System- and access architecture
manufacturing model”. This combined data storage of design
and production data. These procedure is expected to simplify
consistency checks and, even more importantly, ensure equal
architectural rights for design and production aspects. Another
important feature of this architecture is the interface-based
expandability with proprietary design tools (CAD, FEM) and
production planning tools (slicer, toolpath generation).
5. Case study
The following section is concerned with a case study
which demonstrates the integrated design and production
approach. An intuitive solution for the two main steps of the
presented approach is applied for a demonstrator part (hinged
pillar) to illustrate the general concept of the method.
Furthermore, feasible strategies and methods for automating
the approach of an integrated part design and process planning
are proposed
5.1. Combined generation of a part topology (Step 1)
This step begins with a predecessor part shown in figure 4.
The part is separated into part segments, which is currently
done manually based on experiences of the designer.
However, the aim is to develop an automated segmentation
based on a pattern recognition. As next step, all part segments
are assigned to a material (steel, plastic, aluminum etc.) and to
a manufacturing increment (pre-produced part, additive,
subtractive etc.), whereby the classification is based on the
geometry, mechanical load and the connection to other
segments (joints). By assigning different properties to the
respective segments, different component variants can then be
derived. This assignment leads to a tree like structure. The
automated derivation of component variants can be
implemented, on the one hand, based on rules using similarity
indicators and fuzzy logic, and on the other hand, by using
probabilistic methods (e.g. genetic algorithm) to increase the
variety of possible solutions.
 Ann-Kathrin Reichler et al. / Procedia CIRP 79 (2019) 107–112 111
A. Reichler et al. / Procedia CIRP 00 (2018) 000–000

the production route in the manner of a directed graph. For

simple parts with only a few part segments (< 20 part
segments) every potential production route is generated by
permutation. For complex parts (> 20 part segments) with
many part segments it is not efficient to generate all
production routes. One possibility to reduce the number of
production routes in an early stage of the graph creation is the
application of prioritization algorithms for example “Branch
and bound” to prioritize the “fittest” production routes.
The generated production routes must be prioritized and
optimized based on production knowledge. This knowledge
can be generated with the application of different process
models. Currently, the right process model for each part
segment has to be chosen and started manually. For an
automated prioritization, an interface has to be developed to
connect external software products or self-developed
production models (see figure 3). By linking production
models to the production route, it is possible to generate
performance indicators for each production route. Important
performance indicators for IM can be time, quality and costs.
The result of step 2 is therefore a priority list based on
production and technical assessment criteria.
In the end, the generated production knowledge is used as
Fig. 4. Combined generation of a part topology (step1)
feedback for the first step for a further concretization and
elimination of part variants. For example, the overall
Afterwards the generated part geometry has to be
production time for the hinged pillar is reduced from 120 min
optimized and the part behavior has to be simulated. It is
to 5 min using a pre-produced production increment instead of
intended to use topology optimization for additive and
an additive increment as shown in figure 5.
subtractive increments and shape dimensioning and
The last decision about which part variant is the “best part
optimization for pre-produced increments. It is necessary to
variant” will be a compromise between part functionality
develop algorithms for an automated generation of finite
(priority list of functionality) and manufacturability (priority
element models for the shape optimization as well as
list of production technology).
installation design space models for the topology optimization
in order to automate the simulation and optimization process.
Furthermore, an interface is required to link CAD and FEM
programs with the geometry part models to enable an
automated data exchange. The results of the simulation and
optimization procedure can be used to decrease the number of
potential part candidates by eliminating unfavorable variants.
At the end of step 1 a priority list based on the functionality of
the variants is generated.

5.2. Combined generation of a production sequence and

multi-criteria evaluation (Step 2)

During the second step, the functional and geometrically

parameterized part models are supplemented by
manufacturing properties. Due to the combinatorial variety of
sequence candidates, it is desirable to reduce the amount of
combinations for less computational effort. Therefore, the
sequence planning is divided into alternating steps for
(partial) generation of sequence candidates and steps for
prioritizing or excluding these candidates. This procedure is
explained in more detail below.
First, all feasible production routes are generated.
Currently, this is done manually by connecting production
sequences based on human intuition and knowledge about the
process to production routes (see figure 5). For further Fig 5. Combined generation of a production sequence and multi-criteria
evaluation (step 2)
automation, the production routes can be generated by
incrementally adding one process sequence after the other to
112 Ann-Kathrin Reichler et al. / Procedia CIRP 79 (2019) 107–112
A. Reichler et al. / Procedia CIRP 00 (2018) 000–000
Summary
The application of the proposed design and process
planning method based on a simplified demonstrator part can
be summarized as follows:
As first step, the separation process into different
production increments, which are then assigned to specific
materials (e.g. metals, plastic) and manufacturing
technologies (e.g. additive, subtractive) is demonstrated using
a predecessor part of a hinged pillar. Based on this
assignment, it is shown how a multitude of possible part
variants can be generated in a tree-like structure using a
combinatorically variation of manufacturing and material
increments as well as their related joining technology. In
addition, possible methods for future automation of this
procedure are presented.
As a second step, it is shown how feasible production
routes can be generated for each component variant and how
the “fittest” production route can be selected using a multi-
criteria evaluation approach. It is proposed to combine
process models with prioritization algorithms to enable an
efficient and realistic evaluation and selection of production
routes in an automated process.
The application illustrates that in future, automated
processes could be used to design components for incremental
production, which are optimized with regard to
manufacturability (e.g. process cost) and component
functionality (e.g. strength, weight).
6. Conclusion and Outlook
This paper structures the research field for design and
process planning for “Incremental Manufacturing”. A
theoretical method is developed, that solves the challenge of
the rising degree of design freedom. A case study is
conducted where the method is applied using a simplified
example of a hinged pillar and feasible solutions for
automated integration of the method are presented.
The case study presents important functionalities that need
to be further developed for an automated model-based design
and process planning approach for the production concept
“Incremental Manufacturing”.
• Algorithm implementation and evaluation for an automated
variant generation based on an allocation of material and
manufacturing processes as well as an algorithm for
generation of different production routes based on
variation of process sequences.
• Development of a pattern detection to automate the
segmentation of the space model, as an initial step for
every part, which will be designed by applying the
approach to design and processes planning.
• Interface implementation and evaluation for linking
process models for the evaluation of the process routes and
establishment of design tools for the elimination of part
variants.
The further work of the authors will concentrate on the
implementation and evaluation of the listed functionalities for
an automated and integrated design and process planning
method.
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