Methodology for an automatic and early manufacturing technology selection on a component level

Production systems of the automotive industry process parts that were previously designed and manufactured according to different manufacturing technologies. In car body architectures, additive manufacturing (AM) has become a relevant technology for supplementing conventional manufacturing technologies, e.g., casting or forming technologies. This paper presents a methodology for an automatic and objective early-stage analysis of part features and the subsequent identification of the parts’ most suitable manufacturing technology. For this purpose, a comprehensive database is required, in which several technological and economic parameters need to be derived and predicted, including part requirements, production inherences, expected lifecycle costs, as well as geometric information. Based on this, data screening allows to effectively evaluate the technological and economic potential for a component to be manufactured either conventionally or additively in early product development phases. One core element is the part requirements derivation and analysis within one novel module of the part screening methodology. Subsequently, the product development process and the production system can be adapted according to the identified, most promising manufacturing technologies. Hence, this early-stage decision allows for cost reduction through an increased planning reliability. This work thus contributes to a successful co-evolution of smart product development and the production processes.