Increasing adoption of additive manufacturing (AM) makes software support for design for additive manufacturing (DfAM) more relevant. This paper presents a novel, knowledge-driven design support tool for AM that leverages a central knowledge base to provide extensible and powerful DfAM support early in the development process. The approach was implemented using Python for the knowledge base and as a plugin for Siemens NX. It offers automated design checks, optimizations, and further information through an integrated Wiki. Evaluation confirms the feasibility and benefits of the approach.

This paper investigates the use of Large Language Models (LLMs) in engineering complex systems, demonstrating how they can support designers on detail design phases. Two aerospace cases, a system architecture definition and a CAD model generation activities are studied. The research reveals LLMs' challenges and opportunities to support designers, and future research areas to further improve their application in engineering tasks. It emphasizes the new paradigm of LLMs support compared to traditional Machine Learning techniques, as they can successfully perform tasks with just a few examples.

Design sprints complement traditional teaching methods, especially in project-based learning courses. While this approach can potentially change Computer-Aided Design (CAD) usage, it is still underexplored. Therefore, this study explores the influence of design sprints on embodiment-focused CAD activities in project-based learning by examining differences in patterns of CAD user actions, focusing on design space and action types. The case involves two higher-graded and two lower-graded student design teams monitored with a non-invasive method across a two-day design sprint event.

This study envisions a unified paradigm for design for automated disassembly. The goal is to integrate disassembly insights related to precious material recovery with the design phase for sustainable lifecycle management.Targeting plastic products with embedded electronics, the collaboration between design and robotic engineers aims to program a robot for disassembly for the LEGO® motor (45603) as demonstration, emphasizing a disassembly map as a vital tool. By considering the limitations and strengths of robots, this research pioneers a design for disassembly framework.

With recent advancements in Virtual reality (VR), 3D design in VR has gained significant interest from both academia and industries. However, the development of these VR CAD tools is either skewed towards the creative industry or simply mimicking conventional CAD. This paper presents three different tools, analyzes them, and compares their capabilities over various performance parameters. The paper finally suggests where these tools can be used in the design process and some critical pathways for developing VR-based CAD modeling software for practical use in the engineering design industry.

The presented study investigates differences in engineering designers' CAD performance when modelling from two types of projections in technical drawings – isometric and orthographic. The results revealed significant differences in the percentage of correctly replicated components' size and shape, indicating better CAD outcomes when generating CAD models from the orthographic projection. In addition, a comparison of duration, as well as the number and type of sketch entities, sketch relations, and CAD features, showed that CAD modelling processes were similar in both conditions.

This article presents an fNIRS experiment investigating cognitive differences between physical and digital prototyping methods in designers (N=25) engaged in open and constrained design tasks. Initial results suggest that physical prototyping yields increased hemodynamic response (i.e., brain activity) compared to digital design, and that constrained design yields increased hemodynamic response compared to open design, in the prefrontal cortex. Further work will seek to triangulate results by investigating potential correlations to design processes and design outputs.

In HMLV manufacturing, assembly mistakes by operators are common due to the ever increasing product variability and complexity. If mistakes can be detected early-on in the design process, product designers can reduce the possibility for mistakes. We present an algorithm to automatically detect and evaluate potential misplacements of parts that need to be fastened. Evaluation starts from a product CAD and returns the risk of misplacement as well as visual feedback on possible misplacements. An implementation with FreeCAD of our algorithm is illustrated on different use cases.

In the field of 3D model reconstruction, manifold methods have been developed that derive CAD models from 3D scan data. Opposed to classical CAD modelling, where surface and solid modelling exist, a further diversification of modelling techniques is observed, caused by different methods to build up the geometry. This research introduces a new classification, the so-called Level of Complexities. It can be applied to the complete Reverse Engineering process chain and lays the foundation for further research on how to match requirements arising from all process steps and downstream applications.

In objected-oriented design, "smells" are symptoms of code violating design principles. When a deadline is looming, decisions can affect the long-term quality of a code or CAD. Given this and the similarities between object-oriented code and CAD models, this paper introduces a set of CAD smells. These smells are derived from a top-down review of potential CAD smells mapped against the reported code smells that violate abstraction, modularity, encapsulation, and hierarchy principles. This list was further reviewed considering CAD systems and specific examples (some illustrated in the paper).

Manually exploring the solution space for different variants of a product for a given set of requirements is ineffective regarding product development time and adaptation to dynamic customer requirements. Variant generation coupled to optimization algorithms offers possibilities to search the solution space in an automated way. This paper provides a framework to build a generative parametric design environment for functional assemblies by implementing analysis as well as synthesis methods in computer-aided tools. The procedure is presented using the example of a coffee machine.

The integration of additive manufacturing processes into the teaching of students is an important prerequisite for the further dissemination of this new technology. In this context, the DfAM is of particular importance. For this reason, this paper presents an approach in which a connection is made between methodical product development and practical implementation by AM. Using a model racing car as an example, students independently develop significant improvements of particular assemblies. A final evaluation shows that the students have significantly improved their skills and competencies.

During product development, many decisions have to be made that affect the entire product life cycle and often lead to errors that cause additional effort. To proactively support the engineer in evaluating his design in a CAD program, in this paper an approach to evaluate milling designs using a multi-agent system (MAS) is presented. The CommonKADS method is used and the MAS is validated against an application example of a gearbox housing that has been checked for design guidelines, standards, and tool or machine portfolios.

Truss-like shapes can occur in topology optimization described by an assembly of finite elements or its boundary represented as a polygon mesh. Such shape description does not cover a common engineering parametrization like the lines of a frame structure and its corresponding cross-section. This article addresses the truss-parametrization of such optimization using curve skeletons and Meta Balls. While the curve skeleton is common in the truss-parametrization, including Meta Balls can lead to an overall implicit and smooth shape description.

Using the EEG features extracted from the EEG signals, the presented study investigates differences in the cognitive load posed on engineers while 3D CAD modelling in two different conditions, depending on the visual representations used as stimulus - a 2D and a 3D technical drawing of parts. The results indicate a higher cognitive load during the 2D drawing task. In addition, common indicators of the ongoing spatial information processing were recognised - a suppression of parietal and occipital alpha power, a higher frontal theta, and differences in theta power between the hemispheres.

The paper focuses on comparative experiment on manufacturing and inspection of two different prismatic one-off parts, which have different complexity. Our experiment shows that transforming product definition method from the Drawing Centric Definition (DCD) to the Model Centric Definition (MCD) enables 28%-29% time savings in manufacturing and inspection phases of machined one-off part's life cycle. Furthermore, transition from MCD to Model-Based Definition (MBD) enables 5%-9% time savings, respectively. Applying of MBD enables more time savings in complex part compared to a less complex part.

Design for AM (DfAM) requires the definition of Design Actions (DAs) to optimize AM manufacturing processes. However, AM understanding is still very blurred. Often designers are challenged by selecting the right design parameters. A method to list and collect DfAM DAs is currently missing. The paper aims at providing a framework to collect DfAM DAs according to a developed ontology to create databases (DBs). DBs were tested with two real case studies and geometric features to improve identified. Future developments aim at widening the database to provide all-around support for AM processes.

High amount of changes and increasing complexity in CAD design of wiring harnesses result in a lack of time for documentation and transfer of acquired knowledge. To be able to transfer the gained knowledge efficiently during development automating the identification, analyzation and documentation of changes is necessary. This paper shows a methodology to address this challenge for CAD data of wiring harnesses. Thus, it is shown how interrelated change elements can be combined or separated from each other according to their change intention.

The capability to manufacture at home is continually increasing with technologies, such as 3D printing. However, the ability to design products suitable for manufacture and use remains a highly-skilled and knowledge intensive activity. This has led to ‘content creators’ providing vast repositories of manufacturable products for society, however challenges remain in the search & retrieval of models. This paper presents the surrogate model convolutional neural networks approach to search and retrieve CAD models by mapping them directly to their real-world photographed counterparts.

With industries striving towards increased customisation of complex products through engineer-to-order, methods are continuously sought to rationalise the product development process. To this end, a framework is proposed using CAD configurators, utilising design automation and knowledge-based engineering to integrate sales and design processes in product development. The application of this framework to the design of spiral staircases is described and analysed, with results showing decreased lead-times and a decreased risk for design errors.