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The development of additive manufacturing allows the transformation of technological processes and the redesign of products. Among the most used methods to support additive manufacturing, the design can be optimised through the integration of topology optimisation techniques, allowing for creating complex shapes. However, there are critical issues (i.e., definition of product and process parameters, selection of redesign variants, optimised designs interpretation, file exchange and data management, etc.) in identifying the most appropriate process and set-ups, as well as in selecting the best variant on a functional and morphological level. Therefore, to fully exploit the technological potentials and overcome the drawbacks, this paper proposes a systematic redesign approach based on additive manufacturing technologies that integrate topology optimisation and a tool for selecting design variants based on the optimisation of both product and process features. The method leads to the objective selection of the best redesigned configuration in accordance with the key performance indicators (KPIs) (i.e., functional and production requirements). As a case study, the redesign of a medical assistive device is proposed, previously developed in fused filament fabrication and now optimised for being 3D printed with selective laser melting.

The standard method of design and manufacturing customised orthoses is still very time-consuming due to their often very complex shape. Different authors have tried to solve this problem but, unfortunately, the proposed approaches cannot be easily used in clinical practice because they require substantial interaction among medical staff and engineers or technicians. The aim of this work is to present the framework of a new design approach that could allow clinicians to easily model a customised orthosis, without a skilled technician develops the entire procedure. In particular, an automatic process based on Generative Design has been implemented. The obtained results have demonstrated that the implemented algorithm is simple to use and could allow also not-skilled users to design customised orthoses.

This research discusses the use of a systematic design method, the Iterative and Participative Axiomatic Design Process (IPADeP), for the early conceptual design stage of large-scale engineering systems. The involvement of multiple and competing requirements has imposed high challenges for achieving an affordable design of complex systems in a reasonable lead time. Systems Engineering (SE) focuses on how to design and manage complex systems over their life cycles. Both must begin by discovering the real problems that need to be resolved and identifying from the early stage of the design the main stakeholder requirements and customer needs. The Axiomatic Design (AD) methodology is widely recognized in the literature to efficiently support the design of complex systems from the early conceptual stage. IPADeP provides a systematic methodology for applying AD theory in the conceptual design of large-scale engineering systems, aiming to minimize the risks related to the uncertainty and incompleteness of requirements and to improve the collaboration of multi-disciplinary design teams. IPADeP has been adopted as design methodology in the pre-conceptual design stage of a subsystem of the DEMOnstration fusion power plant (DEMO): the divertor cassette body-to-vacuum vessel locking system. In this paper improvements in IPADeP are presented and its validity is discussed by presenting the application to the divertor system design.

Collaborative robotic solutions, where humans and robots share a common workspace performing tasks concurrently without physical safety barriers dividing them, are entering the 4.0 manufacturing market. Some proven and tested use cases of Human-Robot Collaboration have been implemented, but their identification process is often just based on the intuition of planning engineers. The purpose of this work is to propose a systematic approach for the identification of potential collaborative workstations within an industrial production plant. In order to do this a multi-layer modelling approach was used and enriched. The multi-layer approach defines the overall goal of the industrial process, the sub-processes that made it possible, the activity models that enables a flow of activities and, finally, a set of methods to carry out the activities. A morphological box of methods that can be used to achieve the specific goal of identifying suitable collaborative workplaces in an industrial plant, through a process of HRC potential analysis is, therefore, ready to be deeply investigated and used.

Modern digital technologies allow potentially to explore Cultural Heritage sites in immersive virtual environments. This is surely an advantage for the users that can better experiment and understand a specific site, also before a real visit. This specific approach has gained increasing attention during the extreme conditions of the recent COVID-19 pandemic. In this work, we present the processes that lead to the implementation of an immersive app for different kinds of low and high cost devices, which have been attained in the context of the 3dLab-Sicilia project. 3dLab-Sicilia’s main objective is to sponsor the creation, development, and validation of a sustainable infrastructure that interconnects three main Sicilian centres specialized in augmented and virtual reality. The project gives great importance to the cultural heritage, as well as to the tourism-related areas. Despite the presentation of the case study of the Santa Maria La Vetere church, the process of the final app implementation guided by the general pipeline here presented is general and can be applied to other cultural heritage sites.

Applications as robotic harvesting or pick and place in the agrifood domain require robotic grippers able to gently manipulate delicate products, while guaranteeing high gripping power and adhesion forces on smooth surfaces. Existing soft grippers are mainly based on pneumatic bending actuators which can guarantee a gentle manipulation, but they suffer from low gripping power and possibility of slip of the manipulated object. This paper describes a novel design concept of soft robotic pneumatic gripper with embedded suckers. The concept consists of four soft fingers, each one comprising an elastomeric structure with two separate air paths, one for pressurizing the finger for generating bending motion, one for vacuum–based adhesion to the object’s surface via suction pads distributed along the surface of the finger. In this work we highlight the concept design of the mechanical system and the pneumatic control unit.

Emerging production technologies, in particular Additive Manufacturing (AM), nowadays are extremely suitable for creating highly complex products, tending towards the concept of ‘complexity for free’, which is often associated with AM. However, there are no adequate guidelines to provide decision support for the correct selection of the most economically appropriate technology. Indeed, from literature it has been highlighted the need to develop a technology selection methodology based no longer on production volume but on product complexity. This paper investigates this need by presenting an approach to determine the geometrical (or shape) complexity index of a part, which, combined with the assembly complexity, represents the driver for helping to decide the best production technology (traditional or additive). The geometrical complexity index has been determined based on complexity judgments, provided by CAD modelling experts, for a sample of CAD models. In this way, it has been possible to define a preliminary complexity index model, strictly linked to the CAD model information. The results showed that the geometrical complexity metrics from the literature, if individually considered, are not comprehensive. However, a combination of them makes it possible to obtain an index that best reflects the subjective judgement of the experts. In addition, by combining the geometrical and assembly complexity with a cost analysis it is possible to obtain convenience zones for better selecting the production technology. © 2022, The Author(s), under exclusive license to Springer Nature Switzerland AG.

The realization of nuclear fusion reaction as energy source is under investigation, among the scientific community, through the design and development of tokamak reactors. Among the several experiments worldwide, the ITER project is the ma-jor international experiment and it involves several research institutes from sev-eral countries. In such a project, a Systems Engineering (SE) approach is re-quested to organize and manage the design due to its highly integrated design, the safety requirements related to nuclear aspects and the complex procurement scheme. The SE discipline focuses the attention on the requirements which are crucial for every successful project, defining what the stakeholders want from a potential new system, namely what the system must do to satisfy stakeholders need. Correctly stating WHAT is needed for the system, it is possible to obtain its conceptual design (HOW) as much as possible complying the requirements. The incorrect definition of requirements often leads to the failing of a project. Stakeholders’ needs are written in Natural Language that is generally ambiguous, imprecise, incomplete and redundant. Their transformation into SMART require-ments is crucial to avoid design failure. However, it requires a great expertise, unless a specific procedure is assessed. To this end, this work presents a specific procedure based on “like-mind” processes to make systematic the SMART re-quirements definition and assessment from stakeholders needs. The procedure is based on a demand/response framework and it is developed to obtain ITER re-quirements. However, it can be easily extended to every project using its own specifications. A specific case study on ITER Remote Handling is presented in this paper as example of the conceived requirements transformation procedure.

In this study we propose a brief analysis of recent soft wearable robots for upper–limb which could have a major impact on future developments and applications. The systems are analysed with respect to: design concepts, actuation systems, sensing systems, control strategies and applications. Finally, a discussion and open issues are presented.

In the mid-1980s, several metaheuristic methods began to be developed for solving a very large class of computational problems with the aim of obtaining more robust and efficient procedures. Among them, many metaheuristic methods use bio-inspired intelligent algorithms. In recent years, these methods are becoming increasingly important and they can be used in various subject areas for solving complex problems. Firefly Algorithm is a nature-inspired optimization algorithm proposed by Yang to solve multimodal optimization problems. In particular, the method is inspired by the nature of fireflies to emit a light signal to attract other individuals of this species. In this work, a numerical study for solving a structural problem using the Firefly Algorithm as optimization method is conducted. In particular, the implementation of the Firefly Algorithm in several input files realized in the ANSYS Parametric Design Language has allowed the definition of the optimal stacking sequence and the laminate thickness of a composite gear housing used to enclose the components of a mechanical reducer.

Today it is more and more mandatory for all commercial companies to comply with the principles and methodologies of Industry 4.0 and to achieve the related capabilities protecting their competitiveness and taking a leading-edge position on market as regards technologies. Specifically, the whole production and sale system must achieve the fundamental characteristics of Industry 4.0 approach, but specially the manufacturing companies must also change and update their management procedures, internal organization, resource training, assets and all production process to keep safe their current business capacities. This evolution process is even more critical for Small and Medium Enterprises (SME), that traditionally tend to be conservative and to protect their way of operation, usually characterized by a low level of automation. The work presented focuses on the design and integration of a semi-automatic welding cell of train bolster in a SME which is currently realizing a project aimed to the acquisition of Industry 4.0 capabilities, with special focus on manufacturing processes. Among them, one of the most important is the production of welded-steel critical structures, that the Company supplies to prime manufacturer of railway rolling stock systems. The experience gained during the activity, the criticalities due to the integration processes and the adopted design methodologies are here described. The work has been carried out consistently with the Systems Engineering principles, starting from the requirements elicitation and analysis to the systematic approach for the design and integration activities.

Collaborative robotics and additive manufacturing are two enabling technologies of the Industry 4.0 manufacturing paradigm. Their synergic integration requires novel and effective design approaches, aiming to the development of new reconfigurable solutions for customised processes and products. This work presents an integrated approach that exploits the capabilities of Cobots to mimic the repetitive and exhausting operator’s movements as well as the competitive advantages offered by additive manufacturing to realize tailored equipment. In particular, the case study shows the development of a customised device for the manipulation of biomedical components by means of a Cobot, which is introduced in a workstation to replace manual operations. Moreover, the flexibility and the effectiveness of a Cobot can be improved thanks to customised devices for gripping and pick-and-place operations based on a specific application. During the development phase, we simulated the assembly process, and tested different options. The final configuration, with conformal circuits and suction cups, can pick, manipulate and assembly the biomedical components, and thanks to a Fused Filament Fabrication technology is additively manufactured. In conclusion, this developed prototypal solution proves the real capabilities offered by integrating Cobots and additive manufacturing for the lean automation of a biomedical workstation.

Additive Manufacturing is a widespread technology that may enhance product customization based on specific users’ needs, as in the case of assistive devices. Many chronic physical progressively disabling diseases, but also ageing, may cause severe limitations in daily life, which can be overcome by highly customized aids. Literature shows that the active involvement of the patient in the development of assistive devices through co-design allows for their greater therapeutic effectiveness and acceptance. Therefore, this paper proposes a methodological approach for the development of inclusive assistive devices to support daily activities in persons with disabling diseases of the upper-limb. The approach integrates co-design, standardized tools, and low- and high-tech prototyping techniques and tools, which lead to significant feedbacks from patients. The patients are encouraged to interact with conceptual prototypes through direct 3D CAD modelling and touch screen devices. Assessment tests highlight the suitability of the method to achieve the expected goals.

This paper shows how studies on the biomechanics and neuroscience of human movements might be used for the design of wearable systems customized for humans. Such design is driven by key biomechanical and neuromuscular parameters extracted from accurate measurements made on the human body motion, as well as by subjective data collected from the end-users of the products through questionnaires. We present three case studies developed at ERGOS Lab: a wearable system for sports performance analysis; a synergy-based approach for industrial wearable robots; a soft wearable robotic glove for hand rehabilitation.

This paper aims at checking the capabilities of tools to support coding activities for protocol design analysis to improve the efficiency of the process. The application of existing coding schemes to different protocols from real collaborative design sessions allows showing that the approach and the proposed tools can be flexibly adopted for various type of design tasks (product interface design and packaging design). The experiments to check the effectiveness of the proposed tools involved non-expert coders to create challenging experimental conditions and explore. This also allows exploring the viability of approaching the coding stage by non-expert coders in design protocol analysis, with a double goal: the positive results obtained show that is possible to release experts from time-demanding and HR consuming activities and, at the same time, obtain multiple parallel coded protocols for more reliable analysis. The outcomes are also discussed in terms of the implications on the development of similar supporting tools.

Sheet metal parts are widely used in automotive, aerospace, ship and consumer goods industries. The final dimensions of a sheet metal assembly result from the parts deformation, which in turn is affected by many variations in material, thickness and single parts dimensions. The tolerance analysis on sheet metal assemblies improve the knowledge about the process. Advanced simulations enable the optimization of product features, GD&T scheme and assembly process. Moreover, Variational Models of both the product and the assembly system enable to assess the sources of 3D error propagation from the different contributors. However, the simulation results are very affected by the modelling approach of critical components, such as the Fixture Systems. The present paper firstly introduces a strategy to model the Fixture System and the assembly process for compliant parts. Then, a robust analysis of the variations in the model with respect to the modelling factors is performed by a Design of Experiments. A case study on an automotive fender is discussed. The results demonstrate that the modelling strategy of the clamping operation have the main effects, while the modelling of locators scheme, spot joints and FEM meshing are less important.

In the last two decades a huge number of interactive and collaborative applications of Virtual Environments for designing products has been proposed. Such applications have been recommended as tools to implement Human Centered Design Approach in experiments where potential users are involved in participatory design sessions before going for production. In this kind of experiments, we observe that users are mainly involved in the validation of solutions previously elaborated by designers while in the last decade the most innovative approach in the creation of solutions seems to be moving from a user centered design to a co-design or co-creation process. Thus, it is essential to have a platform where the elements of co-creation can be fulfilled in building a successful project. The purpose of this paper is to outline the concept of co creation and the significance of co-creation platforms alongside of proposing innovative tools for building the co-creative environments. The paper aims to layout a classification of the Extended Reality (XR) tools currently available and of their functionality as valuable means to actually embed co-design and co creation concepts in Virtual Environments evaluating the advantages that this can bring to Industry through field studies. A review of innovative solutions like Virtual, Augmented and Mixed reality technologies is examined and drawn towards the requirements of the concept through a literature research. Additionally, a co-creative environment for designing aircraft cabin interiors is conceived and discussed a with company representative.