The geometric freedom allowed by additive manufacturing (AM) has driven the development of products based on human-centric design through functional and aesthetic customization. The combination of personalised AM parts with products already developed is a disruptive and flexible approach that may create optimized product-user interactions. For this, critical comprehension on the manufacturing process is required to ensure appropriate mechanical connection between the new and existing components of the product. This paper addresses a method for product optimization based on this hybrid design approach. A specific case of a musical instrument that was redesigned for greater ergonomic compatibility with users was considered to describe the sequential development steps.

Visual inspection of components, subassemblies and final products is an essential step to ensure the quality control of ready-to-market electronic components. In many manufacturing plants, including Bosch Car Multimedia S.A., typically automated systems for automatic optical inspection (AOI) are implemented at several workstations to perform visual verification and validation in between critical production tasks. At Bosch Car Multimedia S.A., the AOI system includes a metallic support frame that accommodates a series of components for the function of AOI. The support frame is attached to a robotic arm for controlled movement. As the AOI is a rather fast-moving process, deformation of components may occur during monitoring due to the high acceleration of the robotic arm while operating. In addition to this issue, the existent AOI system includes a high number of components and connections which increase complexity for assembly and disassembly operations. This paper presents the redesign for enhanced performance and functionality of a AOI metallic support frame by resourcing to the generative design (GD) exploration method. Furthermore, additive manufacturing technology, based in selective laser sintering (SLS) of polymeric powders, was used for the production of a new lightweight and reliable version of an AOI support frame. The alternative AOI support frame configuration consists of a single consolidated polymeric component that enabled an overall weight decrease above 30% and a reduction of main components and total number of parts of approximately 89% and ∼77%, respectively.

Injection moulding (IM) is a well-known and widely employed fabrication process, which allows the production of versatile and lightweight parts, with precise dimensional tolerance. Multi-material and multi-component products are achieved by means of process variations of the conventional IM. Although the resulting products present combined properties and functionalities, the available techniques require specific machinery and complex tooling design. This paper presents a new processing approach, based in a hybrid method, for the fabrication of multi-material products, with enhanced functionality, based in the combination of IM with additive manufacturing (AM) technologies by means of overmoulding process.

Electrostatic discharge-sensitive devices (ESDS) consist of electronic systems that are easily damaged by electrostatic fields or discharges. To safely stow and transit the ESDS, Bosch Car Multimedia S.A. resorts to thermoformed trays with a specific design for each product configuration. Although efficient, the solutions' specificity arose logistic issues that created the need for an alternative approach. This paper reports the investigation for the development of a flexible tray, based on an electrostatic-dissipative integral skin foam. First, a commercial integral skin polyurethane foam was evaluated by varying components mixing ratio. Once achieved a suitable combination of hardness and density, post-formulation additives (colour and anti-static) were investigated. Free expansion foaming stages were assessed and cured foams were characterised in terms of electrostatic discharge protection. Moulded foams with variable patterns were developed and evaluated considering the application purpose requirements. Real-scale prototypes of the most adequate concept design were produced and analysed.

Improving additive manufacturing (AM) products is important since these technologies still have some limitations that restrict production. These limitations are associated with the size of the build envelope, the materials available and the possibility of multi-material fabrication. For this particular case, there are two different strategies: (i) one, is to build fittings that can act as mechanical connections for different parts, or (ii), to embed the parts as external components in the AM build process of the fittings. This paper presents exploratory research to quickly improve AM ceramic products by AM polymeric fittings in the two strategies presented. The overall aim is to describe a methodology that can optimize products using AM material extrusion technology and that can be used for the production of hybrid products.

A new approach based in a flexible packaging is being analysed to replace a commercial package for the internal transport of variable electrostatic discharge sensitive devices at Bosch Car Multimedia facilities. During the design and fabrication process of a packaging, special attention is given to the handling, by the final consumer, in order to avoid an unusable or inefficient product. This paper presents an exploratory and comparative usability test performed to evaluate the satisfaction concerning several prototype handles, in real context of use. A quantitative evaluation was achieved by means of a specially developed questionnaire with a seven level Likert scale answer, and a qualitative analysis based in the feedback given by the company collaborators. The results indicate that the handle of the actual packaging is inefficient and inadequate for the tasks to be performed, and that two of the developed handle designs are more comfortable and ergonomic.