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In addition to research papers, the Design Society is developing several valuable resources for those interested in the study of design. These include a repository of PhD theses, a library of case studies and transcripts of design activities, and an archive of our newsletters. Please note that these resources are accessible exclusively to Design Society members.

Differential design through adhesive bonding of AM subcomponents

Ascher, Michael; Späth, Ralf

Type:
Papers
DS 145: Proceedings of the DESIGN2026 19th International Design Conference
Year:
2026
Editor:
Štorga, M.; Škec, S.; Martinec, T.; Marjanović, D.; Pavković, N.
Author:
Ascher, Michael; Späth, Ralf
Series:
DESIGN
Institution:
University of the Bundeswehr Munich, Germany
Page(s):
1831-1840
DOI number:
10.1017/pds.2026.10541
ISSN:
2732-527X (Online)
Abstract:
Part separation and subsequent adhesive bonding of additively manufactured (AM) subcomponents is a promising strategy to overcome manufacturing constraints and improve cost efficiency of AM processes. This study presents a three-dimensional scarf joint geometry, designed to maximize bond strength at a minimum use of substrate volume. Based on geometrical measurements, measures for improved accuracy of fit between PBF-LB/M substrates made of AlSi10Mg and Ti6Al4V were derived. Static tensile tests confirmed an almost twofold increase in bonding performance compared to conventional scarf joints.
Keywords:
additive manufacturing, hybrid manufacturing, differential design, adhesive bonding, topological optimisation
DESIGN2026 - The 19th International Design Conference
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