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EDSGN 100 Page 1 of 26

Circuit Card Mount Spring 2018

ADDITIVE AND CUSTOMIZABLE


HARDWARE MOUNT

Jeffrey Mitchell, Michael Maloney, Alejandro Magana, Taylor Wegelin


College of Engineering
Hammond Building
The Pennsylvania State University
University Park, PA

Prepared for
Lockheed Martin

27 April 2018

The Pennsylvania State University


University Park, PA 16802
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Circuit Card Mount Spring 2018

ABSTRACT

The current hardware mounts that are used today lack certain aspects that

Lockheed Martin requires in order to sufficiently fulfill their needs. The aspects

Lockheed is looking for are the ability to easily manufacture the product, adjustability to

allow a wide variety of circuit board shapes and sizes, and finally to avoid cumbersome

mass. Through multiple renditions we decided on a product that we feel best satisfies

Lockheed's needs. Our product, "Rubber Rails", allows for full accessibility from all

angles, 3-D printing, and moveable rails to adjust from medium to small sized circuit

boards. We drafted this product through Solidworks and tested it in a more hypothetical

manner. Through our testing we decided the product will do everything we ask of it.

Therefore, the product successfully accomplishes all needs by iterating off of past

research and previous models.


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CONTENTS

1 EXISTING CONDITIONS ............................................................................................ 6


1.1 Introduction .......................................................................................................... 6
1.2 Identification ........................................................................................................ 6
1.3 Circuit Card Mounts .............................................................................................. 6
1.4 Additive Manufacturing ....................................................................................... 10
1.5 Stakeholder Analysis ......................................................................................... 11
1.6 Summary ........................................................................................................... 11
2 METHODS ................................................................................................................ 11
2.1 Introduction ........................................................................................................ 11
2.2 Concept Generation ........................................................................................... 11
2.3 Ideas................................................................................................................... 12
2.4 Summary ............................................................................................................ 17
3 DATA ANALYSIS ...................................................................................................... 18
3.1 Introduction ......................................................................................................... 18
3.2 Prototype ............................................................................................................ 18
3.3 Testing ................................................................................................................ 19
3.4 Testing Vs. Reality .............................................................................................. 22
3.5 Summary ............................................................................................................ 22
4 CONCLUSIONS ........................................................................................................ 22
4.1 Development ...................................................................................................... 22
4.2 Success of the Product ....................................................................................... 23
4.3 Further Research................................................................................................ 23
5 REFERENCES .......................................................................................................... 25
6 GAANT CHART......................................................................................................... 26
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List of Figures

No. Title Page

1 Panavise pg.
7

2 Quadhands pg. 7

3 Magnifying pg. 8

4 Aven pg. 8

5 Sliding Frame Axonometric Drawing pg. 13

6 Snap Grid Axonometric Drawing pg. 14

7 Leaf Frame Axonometric Drawing pg. 15

8 Pop and Pull Frame Axonometric Drawing pg. 15

9 Rubber Rail Axonometric Drawing pg. 16

10 Front, Side, and Axonometric View of Model pg. 18

11 Model in Standard Position pg. 20

12 Model Being Tilted pg. 20

13 Model showing 360° Rotation pg. 21

14 Model with Circuit Board attached pg. 21


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List of Tables

No. Title page

1 Description of Current Circuit Board Times pg.


8

2 Scoring Table for New Ideas and Control Variable pg. 16

3 GAANT Chart pg. 26


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1 EXISTING CONDITIONS

1.1 Introduction
In the existing conditions section, the following will be discussed: who we are,

why we picked our situation out of the situations presented by Lockheed Martin, the

tabulation of existing circuit card mount features to identify key specifications of design,

the state of Additive Manufacturing, and the improvements we need to make to existing

features of circuit card mounts to meet Lockheed Martin's needs of adjustability and 3D

printing capability.

1.2 Identification

We are four students at the Pennsylvania State University enrolled in

Engineering Design 100. We have varying majors within the engineering program, two

Aerospace, one Biomedical, and one Electrical. We chose to deliver a resolution to the

"Additive Hardware Mount" problem, presented by Lockheed Martin, because three of

our group members have experience soldering. We picked it because we had the

highest level of familiarity with this situation. Lockheed Martin's requirements are, that

the mount must be adjustable for a circuit card of any shape and size and that the

design can be rapidly manufactured by 3D printing.

1.3 Circuit Card Mounts

The existing circuit board mounts all have certain features from which we found

what desirable attributes of a mount are.


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Circuit Card Mount Spring 2018

This model from Panavise has features including 90-degree

tilt and 360-degree rotation as well as single control knob that locks

the holder firmly in place. It comes with a solder station and parts

tray with sponges (Panavise).

Figure 1: Panavise

(http://www.panavise.com/index.html?pageID=1&page=full&--

eqskudatarq=3)

This design includes flexible metal helping hands to

position the card however you want, and the base is hefty

enough that it will not tip over. The mount comes equipped

with rubber feet to reduce sliding and the alligator clamps

have silicon covers. (QuadHands Helping Hands Third

Hand Soldering Tool and vise)

Figure 2: Quadhands (https://www.amazon.com/QuadHands-Helping-Hands-Third-

Soldering/dp/B00GIKVP5K/ref=pd_lpo_vtph_328_tr_t_2?_encoding=UTF8&psc=1&refR

ID=N2Z6ES3BK91PGAGS0Q9C)
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Circuit Card Mount Spring 2018

This product has a heavy cast iron base and holds

the card on alligator clamps attached to four-way swivels.

The adjustable clips and joints allow for movement in all

directions and angles. It comes with a 4x magnifying glass

for precision work. (Eddiestore).

Figure 3: Magnifying (https://www.ebay.com/itm/4X-Stand-Helping-Hand-Magnifier-

Magnifying-Glass-With-2-Clamp-Jeweler-Watch-Tool-

/190926241358?pt=LH_DefaultDomain_0&hash=item2c74173e4e)

Aven's model is retractable to accommodate

boards of varying sizes, the clamps allow for 360-degree

rotation, and it has a rigid metal structure and rubber feet

to ensure stability. (Aven).

Figure 4: Aven (https://www.amazon.com/Aven-17010-Adjustable-Circuit-

Holder/dp/B00Q2TTQEE)

From the products features we compiled the following chart to see how each

product achieved each need, we saw recurring features and picked the ones that

seemed important to the mount design and which we could apply to our design.
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Circuit Card Mount Spring 2018

Table 1: Description of Current Circuit Board Times.

Holding Stability Movement/ Extras


Flexibility
Panavise Long clamps Thick metal base Ball and joint allow -Solder Station
that go along the with a single for 90-degree tilt -Sponge
edge of the knob-controlled and 360-degree -Parts tray
board and lock on ball and rotation
tighten by knob. joint to keep
holder firmly
stationary.
QuadHands Flexible metallic Uses rubber feet Quad hands allow - Silicon Coating
arms with and a heavy for easy mobility of to reduce clamp
alligator clamps base to avoid the circuit card damage
sliding and arms and the hands can
are connected to be easily
base by magnets positioned to the
required areas.
Alligator clamps
can be rotated 360
degrees.
Magnifying Alligator clamps Cast iron base Alligator clamps -Magnifying
very heavy to are on four-way glass for
avoid movement swivel to allow precision when
arms to move 180- working with
degrees small
horizontally and components
360-degrees
vertically
Aven Metal Clamps Uses rubber feet Retractable -Full rotation to
and rigid clamps for varying allow front and
materials board sizes and back visibility
clamps rotate 360-
degrees

From the chart we see that multiple models use rubber feet for stability. This might be

because it is harder for a rubber base to move. To hold the board, we saw a split

between alligator clamps and flat edge clamps that tighten and squeeze the edge of the

board. All models had some degree of rotation allowing the board to be in different

orientations most spinning 360-degrees. Some extra features we found important were
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Circuit Card Mount Spring 2018

sponges, a solder station for the pen, and a parts tray to keep a unified workspace.

Magnification also seems important to working on small boards were precision is

important. From the chart we determined the most important features when designing a

mount are stability, movement, and precision. Existing products achieve stability with

mass but our model needs to achieve the same result and remain light. Current designs

are flexible only to orientation with 360-degree rotation and at least 90-degree tilt so that

the user can work on any component of the board with ease, but they are not very

adaptable to the size of the card. There also needs to be some sort of magnification to

work on small boards with precision, this work requires minute adjustments so stability

and minimizing vibration is needed to mitigate human error.

1.4 Additive Manufacturing

To begin 3D printing a model an electronic design file is configured by using a

CAD or scanner. Then the software being used to 3D print will slice the model into

cross-sectional layers that will allow for a print. The design is then sent to the 3D printer

where the printing process will begin. We intend to use a mix of metal and rubber in our

model, metal specifically has some requirements though. Due to the current state of

metal 3D printing it is important to minimize the amount of sharp turns when possible

because acceleration and deceleration can cause height variations in the model. The

height of the nozzle for depositing the material also is important because if it is too high

the molten metal solidifies before it reaches the surface which will ruin the structural

integrity of the model (Vayre, 633).


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Circuit Card Mount Spring 2018

As described in a 2017 article, "An additive manufacturing-oriented design approach to

mechanical assemblies", there are four characteristics that additive manufacturing has.

They are shape, hierarchical, material, and functional complexity. In the article

functional interfaces (FI) are discussed this interface allows for two things to be

recognized as functional components. They come together to form one component.

1.5 Stakeholder Analysis

Lockheed Martin needs a tool that can adjust to hold circuit cards or other

mechanical objects of any size or shape. It also needs to be capable of quick and easy

manufacturing, while the design needs to be light and capable of also holding hardware

for soldering, reflow, cleaning, and coating. (Mittan, P. (2018)).

1.6 Summary

So far, we have discussed the existing designs of circuit card holders, we

inferred desirable traits by visual observation and their listed features, we compared

them in a table picking out trends to determine the most important aspects of a circuit

card holder, we identified the basic process and stipulations of 3D printing, and we

highlighted the needs of Lockheed Martin.

2 METHODS

2.1 Introduction

In Methods we will explain how we came up with our ideas for a new model,

discuss the functionality of each idea, present detailed annotated sketches of each
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Circuit Card Mount Spring 2018

concept, create a scoring system using what we assumed to be the best existing model

as a benchmark, and then the scoring system will allow us to pick out the highest

scoring model to develop, based off weight categories we will assign.

2.2 Concept Generation

Before we started to generate concepts we first looked at the existing conditions

and what needs were met and what needs were not from the requirements Lockheed

Martin provided us with. Then we established what features of existing conditions were

important to keep and sketched assemblies of these components with different

modifications to meet the adjustability requirement. After that we created as many ideas

as possible to meet the specifications. To narrow down our concepts we went out to

seek professional help. A group member's older brother is an established electrical

engineer, so he was able to show us what concepts were superior to others, specifically

that a continuous backing was not desirable. The continuous backing was not desirable

because it prevented the user from being able to easily access any component of the

board on either side of the board, and if the backing was metal could damage

components of the board. This confined our designs to a top five concepts. Our final

process to narrow our concepts was using a scoring system, that is shown in Table 2.

Using this method, the "Rubber Rails" concept, which is explained in the next section,

had the highest score and was what we used for prototyping
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Circuit Card Mount Spring 2018

2.3 Ideas

The "Sliding Frame" idea came from the desire for a modular design and its ease

to 3D print, which is what Lockheed Martin was looking for. It is adjustable for circuit

boards from 18” x 10” and can slide down to deal with any size chip. The frame is made

up of many connected pieces that can be removed and shrank to the desired size. Each

piece has a track cut into it for the circuit card to rest on. Stability of this model depends

on different materials used and how much money the manufacturer would like to spend.

Figure 5: Sliding Frame Axonometric Drawing

The "Snap Grid Frame" can easily add on modules to make for a bigger area to

work on but can also take modules off for a smaller working area. This model can adapt

to many sizes and shapes while avoiding being a bulky piece of equipment. Because

this mount is alterable, there are spare parts that will need to be stored when not in use.

This particular model would be very stable no matter the material used.
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Circuit Card Mount Spring 2018

Figure 6: Snap Grid Axonometric Drawing

The "Leaf Frame" has a clean simple look to it and can adjust to any size.

This model is a similar idea to a "leaf" dining table. A middle piece can be added by

pulling the main mount apart for bigger projects or, can be taken off and the mount can

be pushed together for smaller projects. This would be a very stable mount because of

its table like nature but may not be the best because you would need to make unique

middle pieces for different board sizes.


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Circuit Card Mount Spring 2018

Figure 7: Leaf Frame Axonometric Drawing

The "Pop and Pull Frame" is a sleek design that can be used with almost any

material. It has full functionality with multiple tiles that can pop and fold under the center

to make different sizes as needed. Unlike the snap grid which removes pieces from the

base these tiles fold underneath so that all the components are connected. The user

can use the middle piece for simple boards or he/she can have four tiles for something

larger, and up to six or nine tiles depending on the size of the project.

Figure 8: Pop and Pull Frame Axonometric Drawing


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Circuit Card Mount Spring 2018

The “Rubber Rail” is a design which pulls the most attractive features of existing

circuit card mounts and adds adaptability. We are using a base that is near identical to

the Panavise because the movement of the ball and joint is very desirable. To modify to

our requirements, we made a track on the upright posts that allows two metal bars with

rubber slits to slide closer together and farther apart for adaptability to circuit card size.

The circuit board will rest in the rubber slits, we decided on rubber because of its friction

which will reduce movement of the board, an idea we took from the rubber feet on the

Quad hands device.

Figure 9: Rubber Rail Axonometric Drawing


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Circuit Card Mount Spring 2018

Table 2: Scoring Table for New Ideas and Control Variable.

Functionality Stability Manufacture Cost (10%) Movement Total


(30%) (20%) Ease (20%) Efficiency (20%)
Panavise 0 0 0 0 0 0
(benchmark)
Sliding Frame +1 -1 +1 +1 0 .4

Snap Grid 0 +1 +1 -1 0 .3
Frame
Leaf Frame -1 +1 +1 +1 -1 0

Pop and Pull +1 0 0 -1 0 .2


Frame
Rubber Rails +1 0 0 +1 +1 .6

From our existing conditions we decided that the Panavise was the most well

rounded current product to be used as a control or bench mark because it has a nice

balance between stability and movement. For the benchmark we gave every category a

score of zero and then for our other models we compared them to the benchmark and if

we felt they were better suited for the client's needs in a category they received a +1

and if we felt they displayed a disadvantage for the client, they received a –1. We

chose categories based off the needs of the client: functionality was for the need of

adjustability, stability was for the need of keeping the card stationary, manufacturing

ease was for 3D printing capability, cost efficiency was to be financially responsible for

our client, and movement was for the need to access any component on the circuit

board. We assigned weight to each category, functionality received 30% because it is

the main goal of this project that the model be adaptable to boards of varying size and

shape. Stability received 20% because there needs to be little movement when making

miniature adjustments, ease of manufacturing also received 20% because the client

specified that it needed to be capable of being 3D printed. Movement received 20%

because it was a key feature of existing models and our product should be just as
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capable. Finally cost efficiency received 10% because a business cost is obviously a

factor but is flexible if it is a high-quality product. We took these weights as fractional

multipliers and multiplied them by the score in the respective category for each concept.

We totaled the weighted scores for each concept and the highest total was the concept

we chose to be our model. The rubber rails concept had the highest score of .6 out of 1

so it is the one we will develop into a prototype.

2.4 Summary
In the Methods section we discussed how we developed original ideas from

existing conditions, narrowed down the concepts to the best ideas, fully described the

functionality of the selected concepts providing annotated sketches of each, detailed a

scoring system in order to select a concept to develop into a prototype, benchmarked

against what we recognized as the best existing model, and then shared the result of

the table.

3 DATA ANALYSIS

3.1 Introduction
In this section we will describe the prototype we developed in detail from sketch

to a physical product, we will state how it works and depict testing on it to verify its

operation, and then we will state the shortcomings of our model and how a life size

model may function differently.

3.2 Prototype
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Figure 10: Front, Side, and Axonometric View of Model.

Our prototype is a 3D model produced in SolidWorks and has a base almost

identical to the existing Panavise model because we liked the split ball idea for

movement, and the parts trey for a unified workspace. The prototype is produced from

the rubber rail concept detailed in section 2.3 that uses two sliding horizontal bars with

rubber slits to hold a circuit card in place. The bars lock in place using a screw and a

wingnut and the rubber keeps the card from sliding within the track when it is rotated.

Also, the ball and joint also has a hole for a wingnut screw to be tightened locking it in

place. We could not 3D print the model because of the limitations 3D printers we had

available to us. The 3D printer could not do multi-material printing and plastic was the

only material option. It also could not print at the desired scale.
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3.3 Testing

The model has the desired movement features, we can rotate it 360 degrees,

however, it does not tilt a full 90 degrees but this was because of the design of the ball

and joint we chose. We did not know how to make a split ball lock in solid works so we

had to modify our concept in a way we could print it. The rails lock by a wingnut screw

that tightens to the upright posts to hold the rail in place. The ball and joint also use a

wingnut screw set up to essentially clamp the ball into a fixed position.

Figure 11: Model in Standard Position.

Figure 12: Model Being Tilted.


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The hand and the arrow demonstrate the degree of tilt the model is capable of

and how it can move on the ball and joint. From this angle you can also see the rubber

track that the board would rest in cut into the rail.

Figure 12: Model showing 360° Rotation.

The uprights were rotated demonstrating the 360-degree rotation along the path

of the arrow. The hand is then shown tightening the screw to lock the ball in place.

Figure 12: Model with Circuit Board Attached.


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This image shows how the rails can be moved apart for a larger board and

shows a hand tightening a screw to hold the rails in place.

3.4 Testing Vs. Reality

If this product was made in a Lockheed Martin facility they would have better 3D

printing equipment being able to print multiple materials on one assembly, so that the

rubber rails could be printed. They also would presumably be able to 3D print screws

and wingnuts so the ball and joint along with the rails would have functional locking

mechanisms. Also, if they were able to use the split ball lock from the Panavise model it

would be able to tilt a full 90 degrees. We would want to print metal for a thicker more

stable base as well, and Lockheed Martin would have access to metal printing. We were

hindered by the quality of the 3D printers we had access to and were not able to make

our model into a 3D print. Lockheed Martin would be able to take our prototype and

develop it into a real product.

3.5 Summary

In Data Analysis we discussed which concept we developed into our prototype,

we used images and clipart along with directional text to show the movement of our

model and how it would work, then we talked about what Lockheed Martin could

improve on if they took our concept and developed it for real.


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4 CONCLUSIONS

4.1 Development
We started by looking at the existing circuit card mounts and analyzed their

features to derive important components for a mount. We made a table to establish

what features we should keep from current mounts and decided that the most important

aspects were stability, movement, and precision. We then established that Lockheed

Martin needed a mount that could be adjustable to hold any card up to 18in x 10in and

could also be 3D printed for rapid build.

Starting with the features we liked from current models we modified the existing

models to fit the requirement of adjustability. We focused less on the 3D printing

because with current technology it is possible to print almost anything and it was more

important to us that we had a solid prototype. Some insight from a group members

brother who is an electrical engineer allowed us to identify that a continuous backing

was undesirable which scrapped a lot of our concepts. From there we made a table with

weighted categories of functionality, stability, movement, ease of manufacturing, and

cost efficiency and used a scoring system to narrow down the remaining five concepts

to one that we would prototype.

4.2 Success of the product


The concept we chose to develop was our rubber rail idea detailed in section 2.3.

We used SolidWorks to model it in 3D but the printer available to us had limited

capabilities so we were unsuccessful in printing the model. We showed the functionality

through a combination of SolidWorks screenshots and clipart with a hand adjusting the

card mount to fit two different sized cards. Theoretically our intervention was successful
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in offering a solution to the problem of adjustability the model if successfully printed

should function as desired and our design in SolidWorks can show the movement it will

have. Unfortunately, we were unsuccessful in creating a physical printable product due

to development constraints. However, Lockheed Martin has the printing capability and

3D modeling knowledge to develop our model into a fully functional product.

4.3 Further Research


If we had more time we would do further research into Additive Manufacturing to

ensure that the difficulties we encountered with not being able to print our model was a

fault of the printer and not the model. We would try to make the file more accessible so

that it could be manufactured on any type of hardware. We would also look into

vibrational damping because precision is required when soldering and we think the size

of our mount would lead to noticeable vibration that could interfere with the users work.

We also did not focus on the requirement for the mount to be lightweight so we would

try to find out how to reduce mass while keeping the same degree of stability. We would

want to get user feedback before presenting our idea to Lockheed Martin to see if the

design is user-friendly and easy to work on. We would want to verify our scoring system

through these user reviews, making sure that the weights we assigned to each category

were appropriate and maybe develop more concepts based on the feedback. Having

subjects use our product would also verify if we were successful in creating a solution to

Lockheed Martin's needs.


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5 REFERENCES

References List

Aven 17010 Adjustable Circuit Board Holder [Digital image]. (n.d.). [Figure 4] Retrieved

March 27, 2018, from https://www.amazon.com/Aven-17010-Adjustable-Circuit-

Holder/dp/B00Q2TTQEE

Eddiestore2008. (n.d.). [4X Stand Helping Hand Magnifier Magnifying Glass With 2

Clamp Jeweler Watch Tool] [Figure 3]. Retrieved March 27, 2018, from

https://www.ebay.com/itm/4X-Stand-Helping-Hand-Magnifier-Magnifying-Glass-

With-2-Clamp-Jeweler-Watch-Tool-

/190926241358?pt=LH_DefaultDomain_0&hash=item2c74173e4e

Panavise. (n.d.). Model: 324 Electronics Work Center [Figure 1]. Retrieved March 22,

2018, from http://www.panavise.com/index.html?pageID=1&page=full&--

eqskudatarq=3

Mittan, P. (2018). Penn State Intro To Engineering Design: Factory Of The Future[PPT].

Lockheed Martin.

QuadHands Helping Hands Third Hand Soldering Tool and Vise [Digital image]. (n.d.).

[Figure 2] Retrieved March 27, 2018, from https://www.amazon.com/QuadHands-

Helping-Hands-Third-

Soldering/dp/B00GIKVP5K/ref=pd_lpo_vtph_328_tr_t_2?_encoding=UTF8&psc=

1&refRID=N2Z6ES3BK91PGAGS0Q9C

Sossou, G., Demoly, F., Montavon, G., & Gomes, S. (2017). An additive manufacturing

oriented design approach to mechanical assemblies. Journal of Computational

Design and Engineering,5(1), 3-18. doi:10.1016/j.jcde.2017.11.005


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Vayre, B., Vignat, F., & Villeneuve, F. (2012). Designing for Additive Manufacturing.

Procedia CIRP,3, 632-637. doi:10.1016/j.procir.2012.07.108

6 APPENDIX

Table 3. GANTT Chart

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