Latticing works by creating a network of meshes and knots that are often compared to a honeycomb structure, a design that is difficult to obtain using traditional manufacturing methods. Other presenters touched on the need for organization-wide disruption as well. Design for Additive Manufacturing: How to Be Successful with High Performance SLS Parts Discover how to optimize your designs for SLS for higher performance parts. Ravi Kunju is quite clear: “, It is the process that dictates how a part is prepared and how it is finished, There are a lot of rules to follow during the design stage to get a proper design for 3D printing: these rules depend strongly on the machine (capacity size, type of technology, material, etc. These programs will take design parameters on load, thermal, or aerodynamic requirements, for example, and then output oftentimes alien-looking features that optimize the solution to a problem. DFAM requires “enterprise-level disruption.” This is how Josh Mook described the changes that have been happening at GE in the wake of additive manufacturing. Using a DFAM approach, that same component could be made as just one part, designed by six to eight engineers, using just one manufacturing source and inspection system, one service shop, and one data lake powered by GE's Predix system. Anatomic Models; D2P Software; Medical Device Design and Manufacturing; Medical Simulation; Point-of-Care Solutions; Virtual Surgical Planning; Dental. How to Design for Additive Manufacturing: Experts give their advice! Tradeoffs are part of the process. We asked three additive manufacturing experts for their opinion on the matter! The advantages of such a design are many, but the main point to remember is that they offer an optimal strength to weight ratio. Instead, they've learned to start with a blank page for additive parts, redesigning rather than adapting, while taking into consideration the material and the machine to be used. As its name implies, additive manufacturing adds material to create an object. “There is a lot of collaboration when we start. Ultimately, it helps companies achieve a new type of business model – transformative, with value by the company that delivers and offers access. However, Ravi Kunju adds that it can be expensive, time consuming and even sub-optimal to alter designs and explore each variation infinitely. 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. “Thermal post-processing relieves the part of residual stresses and, in some cases, alters the grain structure. Example of a lattice structure designed using Dassault Systèmes’ CATIA software | Credits: Dassault Systèmes, For the majority of users, post-processing is often considered a time-consuming, and difficult process. Daniel Pyzak from Dassault adds: “There are a lot of rules to follow during the design stage to get a proper design for 3D printing: these rules depend strongly on the machine (capacity size, type of technology, material, etc.)”. Haptic Devices; Healthcare « Main Menu; Healthcare. Some are not a concern, others are a major concern. The redesign eliminated the leaks by consolidating the valve's five parts into just one additive build. Careful observation and analysis of previous builds made this public test a success. Mechanical post-processing removes the support structure, and finish/drill/mill holes etc. Light-weight, efficient product design is one of the key drivers behind the increasing adoption of additive manufacturing (AM) for series production. Design for Manufacturing; Additive and Subtractive Manufacturing; Inspection; Management; Haptics. Otherwise the down-facing surface quality can be very poor. 7. Topology optimization was a major topic throughout the day, as might be expected at a seminar related to additive manufacturing. Understanding how a part will be used and what is its purpose is of key importance when choosing which design technique(s) to apply – in other words, DfAM is a great way of adding, . Platform. The goal, he says, was not to pull specific parts off the engine and 3D print them. He is the engineering leader GE Additive, the newest business unit at GE, a unit that indicates AM’s disruption with its very existence. For example, if we use DFAM to lightweight a component, then that reduces material costs, decreases build time, lowers machine costs, and saves on pre-/post-processing, all of which lead to a much less expensive metal AM part when using laser … Design for AM, on the other hand, refers to a set of design methods or tools whereby functional performance and/or other key product life-cycle considerations such as manufacturability, reliability, and cost can be optimized to leverage the full capabilities of additive manufacturing … If youâre going to use AM for production, the subtractive steps deserve as much consideration as the additive cycle. Design for Additive Manufacturing with Metals. (DfAM) – developed to optimize the functional performance of the part as much as possible, but also its cost, reliability, and other product life-cycle considerations. Design for Additive Manufacturing: Considerations for Large Parts While additive design for large parts is exciting, it also presents challenges that include the quantity, weight, and traceability of powder; a part’s geometry; the angles of supports; and the printing machine’s capabilities. Compare 3D Scanners Here, no need to remove them! Peter Rogers elaborates on this point: “For additive, the question ‘Can we do that?’ is often answered by a ‘yes’. The need to design existing products more efficiently as well as to optimize them in terms of function and weight are driving the use of additive manufacturing in product design. Dovetailing with Wildman's presentation, Dr. Ted D. Blacker, manager of simulation modeling sciences at Sandia National Laboratories, detailed how topology optimization and simulation could lead to more advanced design methods. You have most probably heard of topology optimization and generative design before. With existing platforms, designers must provide a design in order to make a mesh and start simulations, which are then analyzed so that adjustments can be made. We asked three additive manufacturing experts for their opinion on the matter! The optimized shapes you get from topology optimization are very often impossible to manufacture using traditional processes. But this disruption is about more than business units and reorganization; the way that GE is approaching product development in all of its product lines and industries is changing. In fact, both techniques are often associated. The additive design (AD) and additive manufacturing (AM) of jet engine parts will revolutionize the traditional aerospace industry. is none other than a proven generative design method that is focused on optimizing material distribution using sound numerical methods. A recent DFAM seminar touched on all stages of the additive process. One of the examples given in his talk was a visor custom-made for a race car driver. One of the takeaways: Support structures are worth the effort! Topology optimization must be customized for AM. While it is feasible to do something, it doesn’t mean it should be done that way. 6. DfAM for Teams. Finally, the results of these studies and analysis are incorporated into the design of … Our website uses cookies. Take for example metal 3D printing, and more precisely Laser Powder Bed Fusion technology. There are some lessons that can be applied broadly to most additive technologies, but detailed design advice is heavily dependent on the material and process used, as well as the part's intended function. To begin with, it is important to remember that the design technique(s) chosen will depend on the technology used. Daniel Pyzak explains: “They are design technologies for lightweight engineering serving multiple manufacturing processes: milling, casting, and additive manufacturing.” In short, the final goal of generative design is to arrive at a design that meets performance requirements better, faster, and lighter, using computational methods and resources at-hand. He adds: “, Another way is to integrate these supports (this is the job of the designer, not that of the machine operator) into the design of the part itself. I agree to have my personal data saved in accordance with the privacy policy. Design for Additive Manufacturing All of these following principles differ greatly for each technology category. If any organization in the AM space is adept at this type of knowledge capture, it's Oak Ridge National Laboratory (ORNL). 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. However, Ravi Kunju adds that it can be expensive, time consuming and even sub-optimal to alter designs and explore each variation infinitely. Zwart explained how Caterpillar lacks a central group working on additive manufacturing; instead the company has a central "hub" in its 3D Printing Group, which feeds out information to various spokes—the research, product design and aftermarket groups. 3D Printing with Renewable Materials, Frugally Applied (Video #1), How to Implement Additive Manufacturing Across a Global Company: 5 Lessons, 6 Things I Learned about Metal 3D Printing at the AMIST, Bioceramics for Bone Replacement: The Cool Parts Show S3E2, View the schedule and register for future events here, Building The Future Workforce of Additive Manufacturing, Additive Manufacturing Will Aid And Accelerate The Circular Economy, Four Tips for Moving to Additive Production, team of GE engineers was challenged to redesign a helicopter engine in secret, 10 Valuable Lessons from an Additive Metal Part, 5 Lessons About Additive Manufacturing We Can Learn from This Part, How Topology Optimization Could Be the Key to Longer-Lasting Hip Implants. Finally, our experts focused on the concept of lattice structures, which is a form of optimization since it aims to reduce the weight of a part while maintaining its structural integrity. Abstract. Additive manufacturing helps companies transform the products they offer to the market, including their manufacturing process, supply chains and how they produce products. By using our website and agreeing to this policy, you consent to our use of cookies in accordance with the terms of this policy. Design guidelines for holes, lattices, overhangs, fins, ribs, and nesting. 8. In additive manufacturing, there are very specific design rules and tools that will allow you to create an optimized design, ready for 3D printing. Support structures are expensive to print and remove, considering they have to be subtracted from the final part. A Practical Guide to Design for Additive Manufacturing (Springer Series in Advanced Manufacturing) [Diegel, Olaf, Nordin, Axel, Motte, Damien] on Amazon.com. Mechanical post-processing removes the support structure, and finish/drill/mill holes etc. Additive manufacturing uses data computer-aided-design (CAD) software or 3D object scanners to direct hardware to deposit material, layer upon layer, in precise geometric shapes. In order to understand what DfAMy is and how it differs from DfAM, it helps to begin with the acronym that started it all: DfM. Newsletter. 3Dnatives works with key Additive Manufacturing market players and offers a variety of services such as a 3D printing price comparison engine, B2B consulting and B2B brand content, event management and much more! Over the course of a day, industry experts from AM equipment suppliers, users and national labs spoke about the challenges of designing for additive in the context of their organizations. 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. With lattices, the internal sections cannot be easily inspected, which would mean that the ongoing disadvantages would outweigh the benefits. Job Board Production and manufacturing teams are building out their understanding of the best practices around AM.“, To begin with, it is important to remember that the design technique(s) chosen will depend on the technology used. Evan Kuester, applications engineer for 3D Systems, showcased multiple examples of parts made using selective laser sintering (SLS) in his talk. A team from Altair leveraged simulation, topology optimization and 3D printing to design an optimized hip stem that meets both conditions. However, in medical devices, the shape is relatively set in place, and lattices are more functional for osseointegration, so most DfAM is done using latticing.”. Design for Additive Manufacturing: Complex Geometry This is the first in a seven-part series exploring how the principles of design for additive manufacturing (DfAM) can help unlock the many benefits made possible with metal 3D printing. Home » 3D printing news » Expert Advice » How to Design for Additive Manufacturing: Experts give their advice! Ravi Kunju explains that there are three main types of post-treatment for 3D printing: thermal, mechanical and thermo-mechanical. Thermo-mechanical post-processing could be like hot iso-static pressing (HIP).”, Actually, Daniel Pyzak advises reducing the number of 3D printing supports (or even eliminating them), especially in metal additive manufacturing. Your email address will not be published. is to arrive at a design that meets performance requirements better, faster, and lighter, using computational methods and resources at-hand. He says the engineering team had to learn by experience that they couldn’t just print off a replacement of an existing CAD part and expect it to function the same way as the machined part. Required fields are marked *. After explaining some key changes that were made in the process—such as removing the fenders of the car because they were cooling too quickly compared to the rest of the build, and increasing the extrusion rate of the BAAM system—Post shared that the first successful build of the Strati was the one that happened on the show floor at IMTS 2014. Without the context of the application, it's still difficult to make specific recommendations for AM. Before you design for AM, you need to know which process you are designing for, and if possible, what machine it will be built upon. As a result, the cost of the part dropped by 55 percent, 33 percent of pressure drop was eliminated and noise was reduced. Last month I discussed how Design for Additive Manufacturing (DFAM) is the value multiplier when it comes to additive manufacturing (AM). In the past, Mook explained, a product might have 300 components, take 60 engineers to design and execute, use more than 50 manufacturing sources and 5 repair sources, and integrate 40 data systems. The package combines design capabilities with calculation simulation and immediate feedback for designers. Even so, it's difficult to change the thinking of thousands of employees spread worldwide. "How do you inspire 10,000 design engineers in multiple facilities across the globe?" Peter Rogers explains that an exciting new technology can compare the results if using 3D printing, 2.5, 3, 5-axis machining, and other manufacturing methods to determine which parts are suitable for AM | Credits: Autodesk, Understanding how a part will be used and what is its purpose is of key importance when choosing which design technique(s) to apply – in other words, DfAM is a great way of adding functionality. One of these applications was the 3D printing of very thin "egg shell" molds for silicon casting. When you come to see the failure as a positive, you can capture that knowledge for next time, he says. The app saves time and money during the additive manufacturing process for a 3D printed injector for hybrid rocket engines at Taiwan Innovative Space. With PLATO, it will be possible to work with the physics from the beginning to create the shape of the part, he says. Click the play button to watch a short video on how ASME can help you harness design for additive manufacturing and overcome its challenges. Additive Manufacturing (AM) is fundamentally different from traditional manufacture. According to Levy, there’s a tradeoff between wanting a light part with thin walls and ensuring that it can actually support the loads it will be subjected to. Additive manufacturing thrives on failure. These methods are generally grouped under the term Design for Additive Manufacturing (DfAM) – developed to optimize the functional performance of the part as much as possible, but also its cost, reliability, and other product life-cycle considerations. Compare Professional 3D Printers This eLearning course focuses on all stages of production and manufacturing, including design, post processing, and business considerations. Newer programs, such as generative design or topology optimization, help designers think about creating designs for additive manufacturing technologies. 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. 10. In additive manufacturing, there are very specific design rules and tools that will allow you to create an optimized design, ready for 3D printing. ), For example, in a selective laser melting process to print metal, a support structure is required when printing surfaces that are under 45 degrees. In order to strengthen and keep the visor from cracking, it was necessary to add internal supports that hadn't been necessary in the first design. Work with our additive design team to adapt your design for best results in an industrial 3D printer. Several techniques are used today, such as generative design, topology optimization or the creation of lattice structures. Several techniques are used today, such as generative design, topology optimization or the creation of lattice structures. Zwart answered that his team strives to look at failures as a learning experience. 4. By controlling these variables, it's possible to make topology optimization more productive for additive applications. Specifics are specialized. The optimized shapes you get from topology optimization are very often impossible to manufacture using traditional processes. To take full advantages of unique capabilitie Hip stem implants must support the mechanical loads of the patientâs lifestyle, but should also avoid stress shielding. One method Caterpillar uses is an annual design challenge, in which engineers are tasked with redesigning a component that could be improved via additive manufacturing. The ideal DFAM workflow is actually recursive—it must exist in a feedback loop that includes not only the additive process, but also the material to be used, the parameters of the machine, postprocessing needs, and the essential properties and function of the part. Anet A8 | Anet 3D, Compare Desktop 3D Printers Raymond Wildman, materials research engineer at the U.S. Army Research Laboratory made the point that while the two go hand-in-hand, topology optimization is broader than just additive manufacturing. In order to answer the issues related to DfAM, we asked some questions to Ravi Kunju, SVP, Strategy and Business Development at Altair; Daniel Pyzak, Director, EMEA CATIA Competency Center at Dassault Systèmes; and last but not least Peter Rogers, APAC Product Specialist for Additive Manufacturing at Autodesk. .” Minimizing the number of supports is therefore an important step in DfAM, a point that can also be applied to other 3D printing technologies. Altair provides design software that goes beyond the creation of unique prototypes and provides a robust simulation toolchain to support production designs. Additive manufacturing’s ability to create complex geometry also opens the door to lightweighting parts through the use of lattice-like designs, closed-cell infill and lightweighting features that normally couldn’t be justified with traditional manufacturing. However, in order to benefit from the inherrent opportunities of AM, it is necessary to quantify the fundamental attributes in comparison with traditional methods. This course was designed for early to mid-career engineers, including design engineers, materials engineers, manufacturing engineers, and others with an interest in design for additive manufacturing with metals. In some cases this means designing a part that will print successfully on more than one system, he says, citing a series of dashboard inserts that were originally designed for an FDM system, but later tested and produced successfully on an Objet printer as well. How to choose the right design method to optimize the entire design process of a 3D printed part? Executing proper design for additive manufacturing techniques can increase yield and save time and costs when building your manufacturing process by ensuring that your 3D printers are used effectively. Every wednesday, receive a recap of the latest 3D printing news straight to your inbox. (View the schedule and register for future events here.) Form 3 | Formlabs 1. da Vinci mini w+ | XYZPrinting In some cases extra supports, thicker walls or other design features may be necessary. It's a computational design method that uses an optimization loop to solve a given physics problem, and that solution may or may not be buildable with current additive technologies. Image courtesy SME. Support structures are expensive to print and remove, considering they have to be subtracted from the final part. The best approach is to create designs that have minimal support structures. Jet Fusion 580 | HP Hosted by SME as part of its Smart Manufacturing seminar series, the event took place in Knoxville, Tennessee. 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. asks Zwart. In fact, both techniques are often associated. *FREE* shipping on qualifying offers. How to optimize the design of an example part to save $500 in material costs, 80 hours of machine time, and manual labor time. 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. 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Designs that have minimal support structures are worth the effort my personal data saved in accordance with privacy. To begin with, it is important to remember that the ongoing disadvantages would outweigh the benefits, in cases..., they were able to reduce the final part as possible, from the final part a major.. To print and remove, considering they have to be subtracted from the horizontal expected a. Of employees spread worldwide taking the capabilities of each supplier into account every wednesday, receive recap! Differ greatly for each technology category are not a concern, others are a major topic throughout the day as. Design was based on another driver 's visor, but it ’ definitely... Of previous builds made this public test a success Point-of-Care Solutions ; Surgical... Greatly for each technology category as how to design for additive manufacturing design, post processing, and finish/drill/mill etc! 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