Fuzzy model-based design for testing and qualification of additive manufacturing components
Journal article, 2022

The uncertainties and variation of additive manufacturing (AM) material properties and their impact on product quality trouble designers. The lack of experience in AM technologies renders the experts' assessment of AM components and the establishment of safety margins difficult. Consequently, unexpected qualification difficulties resulting in expensive and lengthy redesign processes might arise. To reduce the risk of qualification failure, engineers might perform copious time-consuming and expensive specimen testing in early phases, or establish overconservative design margins, overriding the weight reduction benefits of AM technologies. In this article, a model-based design method is proposed for the conceptual design of AM space components with affordable test phases. The method utilizes fuzzy logics to systematically account for experts' assessment of AM properties variation, and to provide an early estimation of a product qualification likelihood related to design parameters of interest, without the need for copious testing. The estimation of qualification likelihood can also point out which are the unique AM material uncertainties that require further specific testing, to enable the design of a product with a better performance and more affordable test phases. The method is demonstrated with the design for AM gridded of ion thrusters for satellite applications.

Fuzzy logics

Additive Manufacturing


model-based design


Olivia Borgue

Chalmers, Industrial and Materials Science

Massimo Panarotto

Chalmers, Industrial and Materials Science, Product Development

Ola Isaksson

Chalmers, Industrial and Materials Science, Product Development

Design Science

20534701 (eISSN)

Vol. 8 e11

Consortum for Hall Effect Orbital Propulsion System (CHEOPS)

European Commission (EC) (EC/H2020/730135), 2016-11-01 -- 2020-03-31.

Subject Categories

Production Engineering, Human Work Science and Ergonomics

Aerospace Engineering

Other Engineering and Technologies not elsewhere specified



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