The best approach is to create designs that have minimal support structures. Newsletter. Design for Additive Manufacturing with Metals. Your email address will not be published. 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. Daniel Pyzak explains: “, They are design technologies for lightweight engineering serving multiple manufacturing processes: milling, casting, and additive manufacturin. "How do you inspire 10,000 design engineers in multiple facilities across the globe?" Peter Rogers elaborates on this point: “For additive, the question ‘Can we do that?’ is often answered by a ‘yes’. This concept emerges due to the enormous design freedom provided by AM technologies. The unique characteristics of AM, such as gradient materials and micro-structures, have opened up a new direction in jet engine design and manufacturing. A team from Altair leveraged simulation, topology optimization and 3D printing to design an optimized hip stem that meets both conditions. In additive manufacturing, there are very specific design rules and tools that will allow you to create an optimized design, ready for 3D printing. 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. Course participants are expected to: 4. 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. Evan Kuester, applications engineer for 3D Systems, showcased multiple examples of parts made using selective laser sintering (SLS) in his talk. AM supports a range of light-weighting approaches including generative design techniques such as topological optimisation. The optimized shapes you get from topology optimization are very often impossible to manufacture using traditional processes. 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. During the Q&A segment following his talk, Paul Zwart, market development consultant for AM at Caterpillar, was asked how the company deals with failure. 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. A recent DFAM seminar touched on all stages of the additive process. As a result, Wildman calls for adapting topology optimization to additive manufacturing by focusing on the factors most critical to AM success: minimizing feature size, eliminating support structures and reducing residual stress. A Practical Guide to Design for Additive Manufacturing (Springer Series in Advanced Manufacturing) Anet A8 | Anet 3D, Compare Desktop 3D Printers 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.”. Josh Mook, engineering leader of GE Additive, illustrated the idea of starting from scratch in telling the story of how a team of GE engineers was challenged to redesign a helicopter engine in secret. Support structures are expensive to print and remove, considering they have to be subtracted from the final part. Such a technique also offers shock absorption and impact protection, particularly interesting in cycling, for example. 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. Today, there are very few parts being designed in this way, but it’s definitely a promising idea.”, Another example of the results of generative design, consolidating 8 components into 1 part | Credits: Autodesk, Peter Rogers concludes: “Bringing in the AM knowledge as early into the initial design process as possible will be the key to best leveraging the hardware. 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. asks Zwart. 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. Compare Professional 3D Printers As a result, the cost of the part dropped by 55 percent, 33 percent of pressure drop was eliminated and noise was reduced. Blacker's lab is involved in the development of a software package known as PLATO, or Platform for Topology Optimization. DfAM for Teams. One must add a constraint to ensure that the structure that is generated has surfaces well over the 45-degree angle from the horizontal. If you’re looking to optimize the design of a legacy part, or construct a replacement for a broken component, reverse engineering from a 3D scan can save you days or weeks of manual design. Design guidelines for holes, lattices, overhangs, fins, ribs, and nesting. 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! Hosted by SME as part of its Smart Manufacturing seminar series, the event took place in Knoxville, Tennessee. 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. 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. 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. The best approach is to create designs that have minimal support structures. Design for Additive Manufacturing All of these following principles differ greatly for each technology category. Every wednesday, receive a recap of the latest 3D printing news straight to your inbox. “If there are too many constraints, one may never arrive at an optimal solution. The challenge promotes additive thinking across the organization while generating real results. 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. 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. The goal, Blacker says, is to "turn the analysis and design scenario on its head." Form 3 | Formlabs 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. The components that can be manufactured with additive manufacturing are identified, together with the technologies that are enabled by additive manufacturing to reduce space debris. The mandate to implement "design for additive manufacturing" (or neatly abbreviated: DFAM) is not as simple as designing a part to be built additively. Otherwise the down-facing surface quality can be very poor. 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. Topology optimization was a major topic throughout the day, as might be expected at a seminar related to additive manufacturing. He is the engineering leader GE Additive, the newest business unit at GE, a unit that indicates AM’s disruption with its very existence. 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. We asked three additive manufacturing experts for their opinion on the matter! The redesign eliminated the leaks by consolidating the valve's five parts into just one additive build. 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. In any case, the goal is always to minimize cost and maximize pr… As you will know, a machining piece is not designed in the same way as a 3D printed piece: each manufacturing process is associated with a design technique. Click the play button to watch a short video on how ASME can help you harness design for additive manufacturing and overcome its challenges. 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. 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. ASME’s Corporate Training delivers customized group training held at an organization’s site and is specifically designed to address your company’s issues and challenges. Mechanical post-processing removes the support structure, and finish/drill/mill holes etc. Additive manufacturing thrives on failure. Ravi Kunju explains that there are three main types of post-treatment for 3D printing: thermal, mechanical and thermo-mechanical. All of our online courses are … Topology optimization is none other than a proven generative design method that is focused on optimizing material distribution using sound numerical methods. The app saves time and money during the additive manufacturing process for a 3D printed injector for hybrid rocket engines at Taiwan Innovative Space. “, If there are too many constraints, one may never arrive at an optimal solution. Was this expert advice useful? A Practical Guide to Design for Additive Manufacturing (Springer Series in Advanced Manufacturing) [Diegel, Olaf, Nordin, Axel, Motte, Damien] on Amazon.com. It’s not as simple as changing the manufacturing method. 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. Book a Call. 3. How to Design for Additive Manufacturing: Experts give their advice! 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. x Get on the phone with one of our additive manufacturing specialists to talk about making turning your project into a part today. (View the schedule and register for future events here.) In. The goal, he says, was not to pull specific parts off the engine and 3D print them. Several techniques are used today, such as generative design, topology optimization or the creation of lattice structures. One of the examples given in his talk was a visor custom-made for a race car driver. Designing for manufacturability comes after the initial mechanical and/or electrical design, but before the design is released to the supplier for fabrication. Placing this burden on the software will help engineers move away from being analysts and lead to more creative designs that are optimized for additive manufacturing from the very beginning. 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. With topology optimization, they were able to reduce the final weight of the part by 30% | Credits: Altair. How to optimize the design of an example part to save $500 in material costs, 80 hours of machine time, and manual labor time. Ultimately, it helps companies achieve a new type of business model – transformative, with value by the company that delivers and offers access. In the future, much of DFAM will be automated. Here, no need to remove them! However, Ravi Kunju adds that it can be expensive, time consuming and even sub-optimal to alter designs and explore each variation infinitely. *FREE* shipping on qualifying offers. In some cases extra supports, thicker walls or other design features may be necessary. One of these applications was the 3D printing of very thin "egg shell" molds for silicon casting. Light-weight, efficient product design is one of the key drivers behind the increasing adoption of additive manufacturing (AM) for series production. Required fields are marked *. Last month I discussed how Design for Additive Manufacturing (DFAM) is the value multiplier when it comes to additive manufacturing (AM). Though AM can build intricate, complex shapes, these don’t necessarily come without their own cost. Hip stem implants must support the mechanical loads of the patient’s lifestyle, but should also avoid stress shielding. This eLearning course focuses on all stages of production and manufacturing, including design, post processing, and business considerations. The design was based on another driver's visor, but was taller than the original. 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. This course introduces you to one of the more common applications of generative design: Additive Manufacturing or 3D printing as it’s also known. The shells are injected with silicon, and then broken to release the flexible part. 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. This digital information can then be used to create a new component or directly optimize its design for Additive Manufacturing. With PLATO, it will be possible to work with the physics from the beginning to create the shape of the part, he says. 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. Image courtesy SME. Zwart answered that his team strives to look at failures as a learning experience. Your email address will not be published. .” 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 additive design (AD) and additive manufacturing (AM) of jet engine parts will revolutionize the traditional aerospace industry. By using our website and agreeing to this policy, you consent to our use of cookies in accordance with the terms of this policy. 5. This course introduces you to one of the more common applications of generative design: Additive Manufacturing or 3D printing as it’s also known. Zwart highlighted the winner of the 2016 challenge, a ball check valve for a thermal test rig that was prone to leaking. Instead, the team was challenged to "set the architecture of the engine around additive." Take for example metal 3D printing, and more precisely Laser Powder Bed Fusion technology. Platform. For some context, DfAM emerged because of the enormous design freedom and unique capabilities provided by AM technologies, as opposed to traditional methods such as CNC machining, where some designs are simply impossible to manufacture. The advantages of such a design are many, but the main point to remember is that they offer an optimal strength to weight ratio. One of the takeaways: Support structures are worth the effort! 10. 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. 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. To begin with, it is important to remember that the design technique(s) chosen will depend on the technology used. Additive Manufacturing (AM) is fundamentally different from traditional manufacture. True DFAM involves tradeoffs, specialization and even failure. Without the context of the application, it's still difficult to make specific recommendations for AM. Some are not a concern, others are a major concern. (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. Mark Two | Markforged Several techniques are used today, such as generative design, topology optimization or the creation of lattice structures. As its name implies, additive manufacturing adds material to create an object. Design for additive manufacturing is design for manufacturability as applied to additive manufacturing. 7. Specifics are specialized. 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. You have most probably heard of topology optimization and generative design before. Careful observation and analysis of previous builds made this public test a success. However, Ravi Kunju adds that it can be expensive, time consuming and even sub-optimal to alter designs and explore each variation infinitely. How to choose the right design method to optimize the entire design process of a 3D printed part? 3D Printer Tests Sign up for our free weekly Newsletter to receive all  of the latest news about 3D printing straight to your inbox! Let us know in a comment below or on our Facebook and Twitter pages! 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. Design for Additive Manufacturing with Metals. To take full advantages of unique capabilitie Here, no need to remove them! However, in order to benefit from the inherrent opportunities of AM, it is necessary to quantify the fundamental attributes in comparison with traditional methods. “Thermal post-processing relieves the part of residual stresses and, in some cases, alters the grain structure. Mechanical post-processing removes the support structure, and finish/drill/mill holes etc. Topology optimization must be customized for AM. Software ; Medical simulation ; Point-of-Care Solutions ; Virtual Surgical Planning ; Dental is design for additive applications these was. 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