Axel Nordin

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• Doctor of Philosophy
• Senior Lecturer at Lund University

The use of material extrusion (MEX) has increased rapidly due to the affordability of 3D printers. This has led to a growing demand for improved print quality, high fidelity, strength, or fast print times. In this study, a non-planar approach for better surface quality is investigated. The hardware of a 3-axis MEX printer was developed together wit...

The as-built geometry and material properties of parts manufactured using Additive Manufacturing (AM) can differ significantly from the as-designed model and base material properties. These differences can be more pronounced in thin strut-like features (e.g., in a lattice structure), making it essential to incorporate them when designing for AM and...

This gait biomechanics study investigated stride length (SL), stride duration (SDN), the peak values of ground reaction forces (GRFspeak), required coefficient of friction (RCOFpeak), leg joints’ angles (anglepeak), angular velocity (angvelx.peak), angular acceleration (angaccx.peak), minimum angle (anglemin.) of the foot, and muscles’ electromyogr...

In the original version of the book, the co-author name “Bernardo Vicente Morell” was mistakenly omitted and has now been inserted in the Chapter “General Process Simulations”. The chapter and book have been updated with the changes.

The Project INEX-ADAM -Increasing Excellence in Advanced Additive Manufacturing (INEX-ADAM) is a 3-year European Union (EU) funded project to establish networking and synergy among the five research institutions through identification, planning and implementation of Additive Manufacturing (AM) research tracks. The project is coordinated by the Univ...

In this chapter, three strategic domains of Additive Manufacturing application are presented: tool making, medicine and transportation, with main benefits and results obtained by application of AM. Chapter presents some of on-going or already finished project from mentioned AM application fields.

Simulation of AM products can capture a number of aspects. Apart from the traditional types of simulation of the end product, such as mechanical, thermal and fluid analyses, it is possible to simulate the AM build process. While simulating products intended for AM can sometimes be performed in exactly the same way as with products intended for trad...

To increase industrial adoption, part qualification and certification of the additive manufacturing (AM) process are crucial through geometric benchmarking as well as optimising the properties and process parameters. However, an extensive research gap remains concerning the geometric dimensioning and tolerancing (GD&T) of AM parts. This paper prese...

The materials most commonly used in 3D-printers are in a filament form. This is a barrier for users who want to have new types of filaments with different material compositions. A 3D-printer which can extrude and print directly from the raw material was assembled. Compounding with the common additive types; fibres, and metal powders was performed....

This paper presents an approach for optimizing floor plans using data collected from workplaces and a physics-based planning algorithm utilizing GPU-acceleration. The approach is compared to two approaches based on Genetic Algorithms and Particle Swarm Optimization. Common objectives, such as minimizing distance between related departments and dayl...

Additive manufacturing (AM), which was first applied for rapid prototyping, is now becoming a real option for small-batch production of final products. Further expansion of AM is closely correlated to production costs. AM can only become competitive to traditional manufacturing methods if a product is designed for AM already from the beginning as i...

Functionally Graded Additive Manufacturing (FGAM) is a layered manufacturing process with which the material composition and organization can be achieved within a single volume to enable variable functionalities. In contrast to conventional manufacturing processes, FGAM can produce free-form structures with adaptable, site-specific properties at st...

This biomechanics study explored stride length (SL), duration (SDN), and gait ground reaction forces (GRFspeak), required coefficient of friction (RCOFpeak), joint angle (anglepeak, anglemin), angular velocities (angvelx peak), angular accelerations (angaccx peak), muscle electromyography (EMG) during the dominant leg stance phase (SP) following an...

Stair-ascending at maximum ability is required during emergency evacuations to reach a safe refuge from deep underground structures. We hypothesized that an ascent can last maximum 5 min at the individual’s maximum step rate (SR), and oxygen uptake (V˙O2) would not reach a stable state. This study explored stair-ascending endurance and some physiol...

With the broader industrial application of Additive Manufacturing (AM), designers are facing new challenges in conceptual design for AM. To better understand the problematic, the authors organised a design workshop with six experts in AM. The paper presents the results of the conducted design workshop and discusses the current and future trends in...

This paper describes an approach for designing lightweight components produced through additive manufacturing (AM). Lightweight design is often done through topology optimization (TO). However, the process of manually interpreting mesh-based and imprecise results from a TO into a geometry that fulfils all requirements is complex. To aid in this pro...

All Additive manufacturing (AM) technologies require post-processing to produce parts that are ready for use. This post-processing can range from support material removal, to surface quality improvement, to colouring and painting, and to aging for polymer parts and heat-treatment for metal parts. Throughout the AM industry there is a vast amount of...

Additive manufacturing (AM) encompasses a range of technologies that allows physical components to be made, from virtual 3D models by building the component layer-upon-layer until the part is complete.

Metal powder bed fusion (e.g., direct metal laser sintering, selective laser melting, and electron beam melting) is an AM process in which thermal energy selectively fuses regions of a powder bed. Materials used include stainless steel, tool steel, aluminium, titanium alloys, nickel-based alloys, cobalt chrome, and precious metals such as gold. The...

The design guidelines below apply to laser powder bed fusion metal processes. The guidelines will vary from machine manufacturer and model to machine manufacturer and model so, if in doubt it is recommended to print a test piece to verify each set of design parameters.

This chapter covers activities that are, typically, outside the designer’s influence, but impact the quality of the final part produced.

We have, so far, mostly been talking about using AM for direct part production. However, many industries are now starting to use AM as a way of manufacturing the tooling for conventionally injection molded, cast, extruded, or sheet-metal parts. This means that the final parts are exactly the same as those that they would have previously made with c...

Material extrusion (a.k.a. fused deposition modelling or FDM) is an AM process in which material is selectively dispensed through a nozzle much like a hot-glue gun. Materials used are typically thermoplastic polymers and the part being constructed normally requires support structures for overhanging features. Some system use support material built...

There are several possible purposes for using simulation tools related to AM. The first aim, just as with traditional design analysis, is to simulate the behaviour and performance of a virtual design, and to use this information to either manually or automatically improve the design according to some given criteria. This avoids the time-consuming a...

Always design with the following thought in mind: With the function I am trying to achieve, what is the simplest possible configuration of part(s) that I can print in an orientation to avoid anisotropy? This thought often leads to good possibilities for part consolidation.

The design guidelines in this section apply to almost all polymer AM technologies. Some technologies have specific guidelines that apply only to that technology, and these are discussed in the chapter on design guidelines for specific AM processes.

This chapter describes the main additive manufacturing technologies in use today. Note, however, that new technologies are continuously appearing on the market, so this space is in a continuous state of flux. Some of the technologies also have minor variants such as, for example, a material extrusion which might have one, two, or even more, extrusi...

Additive manufacturing is developing very rapidly. Every few months we see new technologies, new materials, new software, and new AM products coming to market. It is of great importance to those with an interest in AM to keep abreast of some of the upcoming developments as they will, without doubt, affect how we develop future products.

Design for additive manufacturing (DfAM) is when designers seek to create a product design that takes advantage of the unique capabilities of AM. DfAM also respects the specific process constraints of the AM technology that will be used to produce the product. This goes beyond merely re-designing existing parts for AM. Re-design for AM is useful be...

Additive Manufacturing (AM) is a technology that, while removing many of the constraints of traditional manufacturing, imposes some new constraints of its own. Because of this, engineers and designers need to be taught a new set of skills in design for additive manufacturing (DfAM) in order to become competent in designing parts that maximize the b...

A common assumption in product value literature is that authenticity is what contemporary consumers value the most. However, as this paper illustrates, the meaning of authenticity is unclear, and the term appears foreign to product development practitioners. The purpose of this paper is to explore in what ways product development professionals talk...

The aim of this paper is to investigate the challenges associated with the industrial implementation of generative design systems. Though many studies have been aimed at validating either the technical feasibility or the usefulness of generative design systems, there is, however, a lack of research on the practical implementation and adaptation in...

This work considers the development of a new “plane-strain” biaxial loading device for granular rocks through which the full-field investigation of strain evolution at different scales will be possible. Multiscale strain measurements will be accomplished by combining Neutron Diffraction with Digital Image Correlation during plane-strain loading. Th...

Product alternatives suggested by a generative design system often need to be evaluated on qualitative criteria. This evaluation necessitates that several feasible solutions which fulfill all technical constraints can be proposed to the user of the system. Also, as concept development is an iterative process, it is important that these solutions ar...

Generative product design systems used in the context of mass customization are required to generate diverse solutions quickly and reliably without necessitating modification or tuning during use. When such systems are employed to allow for the mass customization of product form, they must be able to handle mass production and engineering constrain...

In recent years, the number of products that can be tailored to consumers’ needs and desires has increased dramatically; there are many opportunities to individualize the colors, materials or options of products. However, current trends indicate that the future consumer will not be satisfied with mere material and color choices, but will desire con...

Grupparbeten utmålas som pedagogiskt fördelaktiga och av Högskoleförordningen följer, att sådana är ett viktigt inslag i civilingenjörsutbildningen. Artikeln presenterar fallgropar och svårigheter som kan aktualiseras liksom ett antal faktorer som är väsentliga vid gruppsammansättning och examination för att optimera det aktiva lärande som ett grup...

In traditional product development, several iterations are usually necessary to obtain a successful compromise between constraints emanating from engineering, manufacturing, and aesthetics. Moreover, this approach to product development is not well suited for true mass-customization, as the manufacturing company remains in control of all aspects of...

Complex product form generation methods have rarely been used within the field of industrial design. The difficulty in their use is mainly linked to constraints – such as functionality, production and cost – that apply to most products. By coupling a mathematically described morphology to an optimisation system, it may be possible to generate a com...

Engineering design problems are most frequently characte-rized by constraints that make them hard to solve and time-consuming. When evolutionary algorithms are used to solve these problems, constraints are often handled with the generic weighted sum method or with techniques specific to the problem at hand. Most commonly, all constraints are evalua...

This Master’s Thesis has shown possible applications of genetic optimization algorithms (GA) within design. A framework for structural optimization with genetic algorithms was built and used to show the possibilities of using GA to create concept designs given just the boundary conditions and requirements of a structure. A comparison between the op...