Choice between virtual model and prototype in additive manufacturing design process

Abstract

 Additive manufacturing (AM) enables the fabrication of 
complex shapes, which are sometimes impossible to get 
from conventional processes. In traditional design processes 
the performance of a part (such as mechanical strength) is 
evaluated by a numerical model (Finite Element computing) 
that is cheaper and quicker to obtain than a physical one. 
Today, when designing an AM dedicated object, it becomes 
easier to manufacture a physical part with exactly the same 
AM metallic process that will be used for the final serial part. 
Therefore, two options can be used to evaluate the performance 
of the part, a numerical model and a physical model. Then 
how to decide between the two options still causes confusion. 
The purpose of this research is to propose a method to help 
designers to make the best choice between numerical model 
and physical model for evaluating a part in a design process. To 
highlight the comparison between these options, our research 
methodology is based on the Design Research Methodology 
(DRM) model and several cases studies. The paper presents two 
case studies that lead to the proposal of a methodology and a 
list of criteria to help designers in comparing Virtual Model and 
Prototype in a given situation, and finally in deciding which 
option fits the best their needs in this context.