One must add a constraint to ensure that the structure that is generated has surfaces well over the 45-degree angle from the horizontal.” Minimizing the number of supports is therefore an important step in DfAM, a point that can also be applied to other 3D printing technologies. The goal, Blacker says, is to "turn the analysis and design scenario on its head." Light-weight, efficient product design is one of the key drivers behind the increasing adoption of additive manufacturing (AM) for series production. is none other than a proven generative design method that is focused on optimizing material distribution using sound numerical methods. Otherwise the down-facing surface quality can be very poor. Take for example metal 3D printing, and more precisely Laser Powder Bed Fusion technology. Here are some of the themes that emerged: True DFAM starts with a “clean sheet of paper.” Brian Levy, design engineer for Joe Gibbs Racing, made this point in talking about his company’s experience moving from traditional manufacturing to AM on many custom racecar parts. The optimized shapes you get from topology optimization are very often impossible to manufacture using traditional processes. There are many numerical techniques and methods available to drive the designs, such as DOE (design of experiments), stochastic methods, genetic algorithms, neural networks etc., all of which have their strengths and weaknesses and can be classified as design study and synthesis (DSS), Thermal post-processing relieves the part of residual stresses and, in some cases, alters the grain structure. A Practical Guide to Design for Additive Manufacturing (Springer Series in Advanced Manufacturing) [Diegel, Olaf, Nordin, Axel, Motte, Damien] on Amazon.com. 3Dnatives is the largest international online media platform on 3D printing and its applications. How to optimize the design of an example part to save $500 in material costs, 80 hours of machine time, and manual labor time. Last month I discussed how Design for Additive Manufacturing (DFAM) is the value multiplier when it comes to additive manufacturing (AM). Starting from the technology itself, you will avoid certain errors and this will allow you to better optimize your surface finish, maximize the mechanical properties of your part and facilitate its cleaning, which in turn means saving time, material and money. Finally, the results of these studies and analysis are incorporated into the design of … By redesigning the complete system from the ground up, GE was able to take advantage of opportunities to consolidate parts and eliminate seals; as a result of their work and the complexity enabled by AM, the new engine included a sand removal system that could increase the lifespan of the engine in a desert environment from 6 months to 2 years. Designing for manufacturability comes after the initial mechanical and/or electrical design, but before the design is released to the supplier for fabrication. Additive Manufacturing (AM) is fundamentally different from traditional manufacture. Ravi Kunju is quite clear: “It is the process that dictates how a part is prepared and how it is finished.” If you own an FDM 3D printer, you will not create your part in the same way as if you owned a metal or SLS 3D printer. Though the printer is capable of finer resolution that would be suitable for other parts, for this application Kuester recommends no thinner than 0.3-mm wall thickness to support the injection molding process, based on iterative design work. There are many numerical techniques and methods available to drive the designs, such as DOE (design of experiments), stochastic methods, genetic algorithms, neural networks etc., all of which have their strengths and weaknesses and can be classified as design study and synthesis (DSS).”, Thanks to Altair’s software solutions, AP Works (an Airbus subsidiary) designed a 3D printed frame for its motorcycle. The unique characteristics of AM, such as gradient materials and micro-structures, have opened up a new direction in jet engine design and manufacturing. 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