DEVELOPMENT OF A NEW PRODUCT DESIGN PROCESS TO IMPROVISE DESIGN FOR MANUFACTURING USING 3D/4D PRINTING TECHNOLOGY

Abstract

Three Dimensional and Four-Dimensional (3D/4D) printing has widespread popularity because of its shape-changing capabilities in various applications. 3D Printing makes only stationary structured products whereas 3D/4D printing enables an object to change its configuration in response with different external stimuli. Researchers from many fields have examined an extensive array of 3D/4D printing using proofs-of-concept. 3D/4D printing needs more advancement in the structural quality and efficiency to satisfy significant industrial applications which ensure cost effective manufacturing. An overview of integrated computation design strategies and its contribution in enhancing efficient use of smart materials in vast applications also presented and concluded with the findings like systematically incorporating sustainability variables into cost- effectiveness analyses with recent advancements in additive manufacturing tailored with human material interaction aids industries to make informed decisions that align with economic goals. Future views are critically explored and encouraging the collaboration with fabrication methods directs research efforts in a way incorporating advanced 3D/4D product design methods that satisfy industry and customer demands. Three Dimensional and Four-Dimensional (3D/4D) printing is an emerging structure creation process that allows for form morphing in response to external triggering chemicals. Many studies currently concentrate on small to medium-sized 3D/4D printing of structural components. As a result, in order to build industry-based large-scale structures, printing capabilities must be increased without sacrificing quality, cost, and speed. Advances in computer-aided design modeling have led to the development of 3D/4D products, which are essential for the large-scale manufacture of structures for various engineering purposes. Furthermore, cost-effective design and quality assurance control techniques, along with obstacles, are highlighted. Researchers previously encountered challenges in achieving high material efficiency and precise control in laser metal wire deposition, such as variability in friction, fluctuations in deposition rates, and inconsistent hardness across different scanning speeds and power settings. This research focuses on the single deposition technique within laser metal wire deposition, evaluating material usage and deposition efficiency by analysing factors like wire feed rate, laser power, and deposition speed. Findings indicate that coefficient of friction increases with higher scanning speeds, particularly at a sliding velocity of 0.5 m/sec. Furthermore, there were considerable changes in hardness and deposition rate, with the largest deposition rate occurring at the lowest scanning speed of 0.4 m/min. The research implications are significant for industries requiring complex, high-quality metal ABSTRACT components, positioning laser metal wire deposition as a key solution for modern manufacturing challenges. Supply chain management is poised for a transformative shift through the adoption of 3D and 4D printing technologies, which enable localized manufacturing, lead time reductions of up to 65%, and inventory cost savings of approximately 67%. These technologies support the growing demand for customized products by fostering a supply chain that is more responsive, adaptive, flexible, efficient, and cost-effective. 4D printing further enhances product lifecycle management by allowing objects to change shape or function over time, improving overall performance and longevity. The proposed impact analysis demonstrates streamlined adaptation of manufacturing processes, contributing to environmental sustainability through significant waste reduction. Integration of high-value design principles and additive manufacturing improved key dimensions like agility, visibility, collaboration, and flexibility by 15–20 points each, while stakeholder support remained strong, with 62.5% endorsing 3D/4D adoption, 67.8% favouring faster delivery, and over 57% supporting digital integration strategies. Conventional manufacturing methods have always been riddled with shortcomings such as wastage of material, design limitations, and added cost of manufacturing. Conventional methods fail to work efficiently with complex geometries, leading to wasteful use of material and longer production time. In contrast to this, the advent of 3D and 4D printing eliminated such shortcomings by improving design freedom, minimization of waste, and enhancing the manufacturing process. Fishbone diagram analysis is used to identifying the influences of mechanical performance, sustainability, and cost. Mechanical testing indicates hardness is up to 70.3, and young's modulus has a high negative correlation with layer height, which influences the structural integrity. Material selection is the determining factor in establishing the balance of durability, flexibility, and adaptability for optimum performance. Sustainability analysis reflects that additive manufacturing minimizes the wastage of material by nearly 30 percent against conventional means, paving the way for environmental-friendly production. Further, a cost analysis has reflected 25 percent lower production costs, so 3D and 4D printing has become more economical. The evidence points out that incorporating design for manufacturing and design for additive manufacturing boosts the efficiency, performance, and sustainability, establishing additive manufacturing as the revolutionary option beyond conventional means.