Purpose: In this study, response surface methodology (RSM) is applied to a three-point bending stiffness analysis of low-cost material (PLA) specimens printed using FDM technology to analyze the performance of different internal lattice structures (Octet and IsoTruss principally). The purpose of this study is to extend the definition from a discrete (lattice) model to an analytical one for its use in subsequent design phases, capable of optimizing the type of cell to be used and its defining parameters to find the best stiffness-to-weight ratio. Design/methodology/approach: The representative function of their mechanical behavior is extrapolated through a two-variable polynomial model based on the cell size and the thickness of the beam elements characterizing it. The polynomial is obtained thanks to several tests performed according to the scheme of RSM. An analysis on the estimation errors due to discontinuities in the physical specimens is also conducted. Physical tests applied to the specimens showed some divergences from the virtual (ideal) behavior of the specimens. Findings: The study allowed to validate the RSM models proposed to predict the behavior of the system as the size, thickness and type of cells vary. Changes in stiffness and weight of specimens follow linear and quadratic models, respectively. This generally allows to find optimal design points where the stiffness-to-weight ratio is at its highest. Originality/value: Although the literature provides numerous references to studies characterizing and parameterizing lattice structures, the industrial/practical applications concerning lattice structures are often still detached from theoretical research and limited to achieving functioning models rather than optimal ones. The approach here described is also aimed at overcoming this limitation. The software used for the design is nTop. Subsequent three-point bending tests have validated the reliability of the model derived from the method’s application.

The following scientific paper aims to analyze in detail the methodology for reverse engineering of a racing motorcycle connecting rod. The objective is to start with a product available on the market as a spare part, reconstruct its CAD model with a high standard of accuracy, then proceed with lightening modifications to arrive at a new, improved design. The innovative aspect of the procedure lies in the fact that in order to ensure accuracy on the order of a tenth of a millimeter during reconstruction, it was decided to use a FARO articulated arm laser to scan the component’s outer surface. By taking advantage of appropriate redesign CAD software (Geomagic Design X), a reconstruction can proceed within the high standard of accuracy imposed. In conclusion, the modifications made through material removal allow an improvement in product efficiency, ensuring high performance.

Design for Disassembly (DfD) and Augmented Reality (AR) have become promising approaches to improve sustainability, by providing efficient delivery and learning assets. This study combines DfD and AR to deliver a method that helps to streamline maintenance processes and operator training. It focuses on a common part in the process industry that requires frequent maintenance and repair. DfD was applied to the pump’s design to ease disassembly and reduce material waste, energy consumption, and maintenance time. AR was used to provide an interactive guide to improve the operator understanding of its internal parts and assembly/disassembly procedures. The resulting DfD-AR led to a reduction in maintenance time and shows potential to deliver better training. This highlights the potential of DfD and AR to enhance sustainability, learning, and productivity. The resulting disassembly sequence was taken to an AR simulation, helping process designers to better understand the procedure and further optimize the solution with other constraints.

The concept of a novel sanitization device specifically designed for helmets used in bike share services is presented in this scientific work. The system uses ozone, a powerful oxidizing agent, to completely remove dust and bacteria from the helmet surface. Throughout the development process, special attention has been paid to the dual initial goals of efficacy in removing dirt and batteries, as well as ease of use related to the device's safety. In fact, today's sharing services are rarely capable of providing adequate disinfection of the tools, which is especially troubling given the most recent years of pandemic caused by Covid-19. The invention of the ozone-based sanitization device addresses the growing concern about hygiene and safety in bike share services. Furthermore, due to its portability and ease of use, the device is a cost-effective and viable solution for use in a variety of settings. A significant contribution to the advancement of sanitization technology and public health is expected with this work.

Background The “drive by wire” mechanism for managing the throttle is not applied to every modern motorcycle, but it is often managed through a steel wire. Here, there is a cam on the throttle control. Its shape allows the throttle opening to be faster or slower and its angle of rotation, required for full opening, to be greater or less. The maximum angle a rider’s wrist can withstand depends on numerous musculoskeletal mobility factors, often limited by falls or surgery. Methods Using a Progrip knob with interchangeable cams allows the customization of a special cam profile, to ensure the best engine response to throttle rotation and ergonomics for the rider. The use of FEA software and lattice structures, allows to realize a lightweight and efficient design, targeted for fabrication with additive manufacturing technologies. Results The cam was manufactured by exploiting MSLA technology. Finally, a dimensional inspection procedure was performed before assembly. The main result is to have obtained a lighter and cheaper component than the original. Conclusions This study has allowed the design of a mechanical component consisting of innovative shape, light weight, and ergonomics. Furthermore, it demonstrates the effectiveness in the use of lattice structures to enable weight optimization of a component while minimizing the increase in its compliance.

This case study aims to develop a new innovative SUV (Sport Utility Vehicle) model exploiting IDeS (Industrial Design Structure), which is an engineering approach conceived to optimize car design projects in the automotive industry like never before. A compact SUV was chosen because it is a type of vehicle that is highly requested by customers, and it is extremely successful in the market due to its versatility. In fact, compact SUVs are mixed vehicles that combine the pragmatism of a car with the typical robustness of an off-road vehicle making them suitable both for urban and off-road scenarios. The following pages will illustrate the steps followed for the realization of the final product using the SDE (Stylistic Design Engineering) method and other various design technologies, such as Quality Function Deployment (QFD), Benchmarking (BM) and Top Flop Analysis (TPA). In the final part of this project, the virtual prototyping of the product is carried out using Additive Manufacturing (AM) with an FDM 3D printer. The combination of these methods forms, to all intents and purposes, the IDeS, a newly developed innovative and cutting-edge discipline capable of schematically guiding the new product development process in companies with unprecedented efficiency.