Design Process Deconstructed: The Industry Case of an Elevator Button Assembly Redesigned for Additive Manufacturing

Additive manufacturing (AM) has during the 21st century gradually shifted from prototyping towards the manufacture of end-use quality parts. The drivers to utilize AM instead of conventional manufacturing methods are often linked to geometrical design freedom, increased performance, customization, part consolidation, and weight reduction. However, designers have struggled to take full advantage of these new capabilities. In part, this is due to a pervasive engineering mindset locked into the constraints of conventional manufacturing technologies. Another reason is the lack of efficient design methodologies that would take into account the new capabilities of AM.

In this paper, to address the latter deficiency, an assembly redesign process for AM is deconstructed and analyzed. The studied assembly is an elevator accessibility button, which is a high-mix low-volume product. From the industry perspective, AM could reduce costs and increase the agility of production. Through systematic requirements mapping, part- and product-level functional analysis, a holistic functional analysis of the product is composed. The results of the product functional analysis are illustrated in a visual 3D design space. The 3D illustration is suggested as a conceptualization tool for the designers and as a way to reinforce creativity in the design process. The usability and expandability of the tool are discussed and contrasted with the current design methodologies for AM.