From Experience-based to Knowledge-Driven Design: A Case Study of a 3D-Printed Product

DS 122: Proceedings of the Design Society: 24th International Conference on Engineering Design (ICED23)

Year: 2023
Editor: Kevin Otto, Boris Eisenbart, Claudia Eckert, Benoit Eynard, Dieter Krause, Josef Oehmen, Nad
Author: Højeng-Swensson, Jakob; Pisinger, Victor Mathias; Juul-Nyholm, Herle Kjemtrup; Legarth, Brian Nyvang; Eifler, Tobias
Series: ICED
Institution: Technical University of Denmark
Section: Design Methods
Page(s): 1955-1964
DOI number:


In this paper, a case study of a redesign process for 3D-printed parts has been analysed. The purpose was to compare the implementation of specialist knowledge in hands-on engineering tasks with the previous experience-based approach. Here, specialist knowledge refers to systematic experimental work as a basis for Computer Aided Engineering (CAE). The case involves a set of compliant arms for an oil extraction device developed by a start-up company. Tensile tests of 3D printed dog-bone were performed to characterise the Young's modulus, tensile strength, and orthotropic behaviour of the material to build a material model based on Finite Element Analysis (FEA). With the material characteristics and three simple tests to estimate the optimisation constraints, the existing solution was disproven. Then, new solution candidates were generated and evaluated with input from the start-up company. The process resulted in a feasible solution as well as a reduction of maximum stress from 54MPa to 20MPa. The case highlights the value of specialist knowledge for characterisation of new technologies and design space constraints to reduce and improve iterations to solve a practical design problem.

Keywords: Simulation, Design practice, Design process, Case study, 3D printing

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