Facilitating consumer involvement in design for additive manufacturing / 3D printing products

245 Pages·2017·14.49 MB·English

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Facilitating consumer
involvement in design for
additive manufacturing / 3D
printing products
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Additional Information:
• A Doctoral Thesis. Submitted in partial fulfilment of the requirements
for the award of Doctor of Philosophy of Loughborough University.
Metadata Record: https://dspace.lboro.ac.uk/2134/21763
Publisher: (cid:13)c Yudhi Ariadi
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Loughborough University
Loughborough Design School

Facilitating Consumer Involvement in Design for
Additive Manufacturing / 3D Printing Products
by
YUDHI ARIADI

Doctoral thesis submitted in part fulfilment of the requirement for the award of
Doctor of Philosophy of Loughborough University

© Yudhi Ariadi 2016
Abstract
This research investigates the potential of the general public to actively design their
own products and let consumers either manufacture by themselves or send the files
to manufacturers to be produced.
This approach anticipates the rapid growth of fabrication technology, particularly in
Additive Manufacturing (AM)/3D printing. Recent developments in the field of
AM/3D printing have led to renewed interest in how to manufacture customised
products and in a way that will allow consumers to create bespoke products more
easily. These technologies can enhance the understanding of non-technology
compliant consumers and bring the manufacturing process closer to them.
Consequently, to make AM/3D printing more accessible and easier to employ by the
general public, design aspects need to be developed to be as simple to operate in the
same manner as AM/3D printing technologies. These technologies will then attract
consumers who want to produce Do-It-Yourself (DIY) products.
This study suggests a Computer-aided Consumer Design (CaCODE) system as user-
friendly design software to simplify the Computer Aided Design (CAD) stages that are
required to produce 3D model data required by the AM/3D printing process. This
software will be an easy-to-operate design system where consumers interact with
parameters of designed forms easily instead of operating conventional CAD. In
addition, this research investigates the current capabilities of AM/3D printing
technologies in producing consumer products.
To uncover the potential of consumer-led design and manufacturing, CaCODE has
been developed for consumer evaluation, which is needed to measure the
appropriateness of the tool. In addition, a range of consumer product samples as
pens has been built using a range of different materials, AM/3D printing technologies
and additional post-processing methods. This was undertaken to evaluate consumer
acceptance of the AM/3D printed product based on products’ perceived quality.
Forty non-designer participants, 50% male and 50% female, from 5 to 64 years old,
6-7 participants per ten-year age groups in 6 groups, were recruited.
iii
Abstract
The results indicated that 75% of the participants would like to design their own
product using consumer design software. The study compared how consumers
interacted with the 3D model to manipulate the shape by using two methods: indirect
manipulation (sliders) and direct manipulation (drag points). The majority of the
participants would prefer to use the direct manipulation because they felt it was easy
to use and enabled them to enjoy the design process. The study concluded that the
direct manipulation was more acceptable because it enabled users to ‘touch’ the
digital product and manipulate it, making it more intuitive and natural. The research
finds that there is a potential for consumers to design a product using user-friendly
design tools. Using these findings, a consumer design tool concept was created for
future development.
The study indicated that 53% of participants would like to use products made by
AM/3D printing although they still wanted the surface finish of injection moulded
parts. However, the AM/3D printing has advantages that can fulfil the participants’
preference such as multi-materials from the material jetting method and it is proved
that additional post-processing can increase participants’ acceptance level.
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Acknowledgement

I would like to thank my supervisor Dr. Mark Evans and Dr. Ian Campbell for their
continuous support, guidance, advice and also for their patience and encouragement.
My examiners, Professor Richard Bibb and Professor Olaf Diegel for reviewing,
discussion and valuable feedback for my thesis. Dr. Guy Bingham, as my independent
assessor, for his assessment and advice.
To Loughborough University, for funding my studies, to the staff of Loughborough
Design School for their support over the last five years.
To Graduate School for developing my research skills and to Research Student Office
for supporting my study processes. To the Student Advice and Support Service for
their valuable assistance in solving my student life problems.
To friends from Bridgeman Building ZZ 0.21 and LDS 1.23 who made my time at
Loughborough such an enjoyable experience and to empathise with about the PhD
experience.
To my parents, mother and father in law (who is no longer here to see the finished
result) for their encouragement and prayers.
To my lovely wife, Fira Hermawati for love and support throughout my PhD studies;
and to my beloved son, Kenar Narayaka for balancing my student life.

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Publications
Campbell, R.I., Ariadi, Y. and Evans, M.A., 2014. ‘Facilitating Consumer Involvement
in Design’, in: International Conference on Additive Technologies (ICAT),
Vienna, Austria. Presentation.
Campbell, R.I., de Beer, D.J., Mauchline, D.A., Becker, L., van der Grijp, R., Ariadi, Y.
and Evans, M.A., 2012. ‘Additive Manufacturing as an Enabler for Enhanced
Consumer Involvement’, in: Rapid Product Development Association of
South Africa (RAPDASA), Kwa Maritane, Planesberg National Park.
Ariadi, Y., Campbell, R.I., Evans, M.A. and Graham, I.J., 2012. ‘Combining Additive
Manufacturing with Computer Aided Consumer Design’, in: 23rd
International Solid Freeform Fabrication Symposium, Austin, Texas, US, pp.
238-249.
Sinclair, M., Campbell, R.I., Ariadi, Y. and Evans, M.A., 2011. ‘AM-enabled Consumer
Design’, in: Rapid Product Development Association of South Africa
(RAPDASA), Vanderbijlpark, South Africa.

Awards
3rd place best Research Snapshot
Ariadi, Y., Campbell, R.I. and Evans, M.A., 2013. ‘Can consumers design and
manufacture products by themselves?’ East Midlands Universities
Postgraduate Research Student Conference 2013, University of Derby, UK.
Highly commended Poster
Ariadi, Y., Campbell, R.I. and Evans, M.A., 2013. ‘Can consumers design and
manufacture products by themselves?’ Loughborough University Research
Conference, Loughborough, UK.
Highly commended Poster
Ariadi, Y., Campbell, R.I. and Evans, M.A., 2012. ‘Computer-aided Consumer Design
for Additive Manufacturing / 3D Printing Products’. Loughborough University
Research Conference, Loughborough, UK.
Best Poster
Ariadi, Y., Campbell, R.I. and Evans, M.A., 2011. ‘Investigating the potential of
Consumer Design and exploring the possibility for customers to undertake all
of the product creation process from design to manufacture’. Loughborough
Design School Research Student Conference (DeSReS), Loughborough, UK.
Loughborough University Ph.D. Studentship, sponsored by Loughborough University,
UK.
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Table of Contents
Certificate of Originality, Thesis Access Conditions and Deposit Agreement .......... ii
Abstract ...................................................................................................... iii
Acknowledgement ................................................................................................ v
Publications ...................................................................................................... vi
Awards ...................................................................................................... vi
Table of Contents ................................................................................................ vii
List of Figures ...................................................................................................... xi
List of Tables ..................................................................................................... xv
CHAPTER 1 Introduction .................................................................................... 1
1.1 Design and manufacturing by consumers......................................................... 1
1.2 Aims and objectives .......................................................................................... 6
1.3 Structure of Thesis and Research Phases ......................................................... 7
CHAPTER 2 Literature Review: Consumer Design and Manufacturing ................ 9
2.1 Industrial Design, Product Design and Consumer Design ...............................11
2.2 Consumer Design ............................................................................................13
2.2.1 Co-design or co-creation ..................................................................... 13
2.2.2 Personalisation, Customisation and Individualisation ........................ 14
2.2.3 Mass customisation: the four faces and five continuum strategies ... 15
2.2.4 Craft consumption ............................................................................... 20
2.2.5 From consumerism, prosumerism to customerism ............................ 21
2.3 CAD progression: from industry to designer then consumer .........................22
2.3.1 Design tools progression ..................................................................... 22
2.3.2 CAD and human computer interaction (HCI) devices ......................... 26
2.4 Current CAD capability to build consumer design software ...........................29
2.4.1 A geometric modelling kernel ............................................................. 29
2.4.2 Application programming interface (API) ........................................... 30
2.4.3 Programming language ....................................................................... 31
2.4.4 Visual Programming Language (VPL) .................................................. 32
2.4.5 3D app creators ODO-UCODO ............................................................. 33
2.5 Consumer Manufacturing ...............................................................................35
2.5.1 DIY ....................................................................................................... 36
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Table of Contents
2.5.2 AM/3D printing for consumer manufacturing .................................... 38
2.5.3 Manufacturing technology progression .............................................. 39
2.5.4 Consumer manufacturing via internet ................................................ 45
2.5.5 The availability of AM/3D printing technologies for consumer
manufacturing ..................................................................................... 47
2.5.6 Additional post-processing: Enhancing AM/3D printing to produce
consumer products ............................................................................. 56
2.6 Recent development in areas of consumer design and manufacturing .........58
CHAPTER 3 Research Methodology ................................................................. 63
3.1 Theoretical foundation ...................................................................................63
3.2 Research design stages ...................................................................................64
3.2.1 Research paradigm .............................................................................. 64
3.2.2 Research purpose ................................................................................ 65
3.2.3 Research strategy ................................................................................ 66
3.2.4 Research type ...................................................................................... 67
3.2.5 Research method ................................................................................ 68
CHAPTER 4 Development of Consumer Design Software and an AM/3D Printed
Consumer Product......................................................................... 73
4.1 CaCODE Development.....................................................................................74
4.1.1 Creating the pen design ...................................................................... 76
4.1.2 Building the CaCODE:PenCAD ............................................................. 77
4.2 Creating a range of samples ............................................................................82
4.2.1 Process and material selection ........................................................... 82
4.2.2 Developing pens with different processes, materials and additional
post-processing ................................................................................... 85
CHAPTER 5 Consumers’ acceptance of CaCODE and AM/3D printed pens ........ 91
5.1 Recruitment and strategy ...............................................................................91
5.1.1 Study protocol ..................................................................................... 92
5.1.2 Willingness to design ........................................................................... 95
5.1.3 Willingness to use CaCODE ................................................................. 96
5.1.4 Willingness to make a consumer product ........................................... 97
5.1.5 Evaluating the appearance of the AM/3D printing pen ...................... 99
5.1.6 Willingness to use AM/3D printing to manufacture their own products
........................................................................................................ 100
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Table of Contents
5.1.7 Willingness to pay ............................................................................. 100
5.1.8 Keep the product longer ................................................................... 101
5.1.9 Using web-based survey.................................................................... 102
5.1.10 Presenting data ................................................................................. 103
5.1.11 Pilot Study ......................................................................................... 104
5.2 Survey results ................................................................................................111
5.2.1 Participants’ profiles ......................................................................... 111
5.2.2 Intention to design a consumer product .......................................... 112
5.2.3 Willingness to use CaCODE ............................................................... 119
5.2.4 Participants’ preference for 3D manipulation methods ................... 123
5.2.5 Intention to make a consumer product ............................................ 125
5.2.6 AM/3D printed pens rank ................................................................. 131
5.2.7 Willingness to pay for AM/3D printing products .............................. 133
5.2.8 Willingness to use AM/3D printing ................................................... 135
5.2.9 Personalisation and sustainability ..................................................... 140
5.2.10 Participants’ feedback ....................................................................... 141
CHAPTER 6 Discussion ................................................................................... 142
6.1 Consumer design software and its potential market ...................................143
6.1.1 Group 1, who had both design intention and experience and their
response on CaCODE ......................................................................... 143
6.1.2 Group 2, who have had design intention, but never went on to design,
and their response to CaCODE .......................................................... 144
6.1.3 Group 3, who did not have an intention to design and their response
to CaCODE ......................................................................................... 145
6.1.4 Three groups acceptance of CaCODE comparison ............................ 145
6.2 AM/3D printing and its potential market for general public ........................145
6.2.1 Group 1, had intention and experience in making a consumer product,
and their response to AM/3D printing technologies ........................ 146
6.2.2 Group 2, had intention to make but never produced a consumer
product and their response to AM/3D printing technologies .......... 147
6.2.3 Group 3, did not have any intention to make and their response to
AM/3D printing technologies ............................................................ 147
6.2.4 Three groups’ acceptance of AM/3D printing comparison .............. 148
6.3 Consumer Design and Manufacturing ..........................................................148
6.3.1 Consumer design requirements ........................................................ 148
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Table of Contents
6.3.2 Consumer manufacturing requirements........................................... 151
6.4 Consumer design adds sustainability value ..................................................152
6.5 Willingness to pay and actual cost of AM/3D printed pens .........................153
6.6 Research evaluation ......................................................................................153
CHAPTER 7 Conclusion and Recommendation ............................................... 156
7.1 Conclusions ...................................................................................................156
7.2 Contribution to knowledge ...........................................................................160
7.3 Recommendations for Future Work .............................................................161
References ................................................................................................... 163
Appendices ................................................................................................... 191
Appendix A – Pen development ........................................................................ 192
Appendix B – Grasshopper script ....................................................................... 194
Appendix C – Cost for manufacturing a pen in PA and metal material by AM/3D
printing manufacturers ............................................................... 196
Appendix D - Pilot Study questionnaire ............................................................. 201
Appendix E – Main study questionnaire ............................................................ 206
Appendix F – Pen designs by consumers ............................................................ 219

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