Anet A8 | Anet 3D, Compare Desktop 3D Printers 5. 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. Additive manufacturing helps companies transform the products they offer to the market, including their manufacturing process, supply chains and how they produce products. 3. In some cases extra supports, thicker walls or other design features may be necessary. 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. With PLATO, it will be possible to work with the physics from the beginning to create the shape of the part, he says. 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. 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. 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. 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. Ultimately, it helps companies achieve a new type of business model – transformative, with value by the company that delivers and offers access. 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. 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. If any organization in the AM space is adept at this type of knowledge capture, it's Oak Ridge National Laboratory (ORNL). 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. RenAM 500 M | Renishaw 2. 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. is none other than a proven generative design method that is focused on optimizing material distribution using sound numerical methods. 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. 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. Today, there are very few parts being designed in this way, but it’s definitely a promising idea. When you come to see the failure as a positive, you can capture that knowledge for next time, he says. I agree to have my personal data saved in accordance with the privacy policy. 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. Such a technique also offers shock absorption and impact protection, particularly interesting in cycling, for example. Blacker's lab is involved in the development of a software package known as PLATO, or Platform for Topology Optimization. Instead, the team was challenged to "set the architecture of the engine around additive." 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. 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. With topology optimization, they were able to reduce the final weight of the part by 30% | Credits: Altair. While it is feasible to do something, it doesn’t mean it should be done that way. A Practical Guide to Design for Additive Manufacturing (Springer Series in Advanced Manufacturing) [Diegel, Olaf, Nordin, Axel, Motte, Damien] on Amazon.com. 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. Get on the phone with one of our additive manufacturing specialists to talk about making turning your project into a part today. Ravi Kunju explains that there are three main types of post-treatment for 3D printing: thermal, mechanical and thermo-mechanical. x Industrial 3D Printer; Materials. In large organizations that can be difficult, so putting together a working group with people of various backgrounds can help to find new, innovative ways to improve parts and turn what was originally implemented as “thought leadership” technology into an irreplaceable production technology.”. 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. M200 Plus | Zortrax Engineering teams at design and manufacturing firms, as well as individuals. Required fields are marked *. 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, . In the future, much of DFAM will be automated. Tradeoffs are part of the 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.)”. AM supports a range of light-weighting approaches including generative design techniques such as topological optimisation. Other presenters touched on the need for organization-wide disruption as well. Design for Additive Manufacturing All of these following principles differ greatly for each technology category. However, Ravi Kunju adds that it can be expensive, time consuming and even sub-optimal to alter designs and explore each variation infinitely. 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. Your email address will not be published. “, If there are too many constraints, one may never arrive at an optimal solution. Design for additive manufacturing demands changing thinking as well as process, as attendees of SME’s Smart Manufacturing seminar learned over the course of the day. 3Dnatives is the largest international online media platform on 3D printing and its applications. 1. da Vinci mini w+ | XYZPrinting 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. 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. SLM 500 | SLM Solutions Design guidelines for holes, lattices, overhangs, fins, ribs, and nesting. Talk to an Additive Expert. ), For example, in a selective laser melting process to print metal, a support structure is required when printing surfaces that are under 45 degrees. It is a general type 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 subjected to the capabilities of additive manufacturing technologies. Even so, it's difficult to change the thinking of thousands of employees spread worldwide. Additive manufacturing thrives on failure. Let us know in a comment below or on our Facebook and Twitter pages! As a result, the cost of the part dropped by 55 percent, 33 percent of pressure drop was eliminated and noise was reduced. 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. 6. .” Minimizing the number of supports is therefore an important step in DfAM, a point that can also be applied to other 3D printing technologies. In fact, both techniques are often associated. Several techniques are used today, such as generative design, topology optimization or the creation of lattice structures. The mandate to implement "design for additive manufacturing" (or neatly abbreviated: DFAM) is not as simple as designing a part to be built additively. *FREE* shipping on qualifying offers. The additive design (AD) and additive manufacturing (AM) of jet engine parts will revolutionize the traditional aerospace industry. Design for Additive Manufacturing with Metals. Ravi Kunju explains: “For example, in a selective laser melting process to print metal, a support structure is required when printing surfaces that are under 45 degrees. 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. Design for Additive Manufacturing (DfAM) is the process of adjusting your design to make it cheaper, faster, or more effective to manufacture. Here, no need to remove them! 3D Printer Tests 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 app saves time and money during the additive manufacturing process for a 3D printed injector for hybrid rocket engines at Taiwan Innovative Space. 8. “Thermal post-processing relieves the part of residual stresses and, in some cases, alters the grain structure. In. Newsletter. Design for Additive Manufacturing with Metals. True DFAM involves tradeoffs, specialization and even failure. 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.”. The package combines design capabilities with calculation simulation and immediate feedback for designers. Every wednesday, receive a recap of the latest 3D printing news straight to your inbox. The advantages of such a design are many, but the main point to remember is that they offer an optimal strength to weight ratio. How to choose the right design method to optimize the entire design process of a 3D printed part? 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. 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. A recent DFAM seminar touched on all stages of the additive process. In additive manufacturing, there are very specific design rules and tools that will allow you to create an optimized design, ready for 3D printing. With its in-depth analysis of the market, 3Dnatives gets over 1 million unique visitors per month and is currently available in English, French, Spanish, and German. Careful observation and analysis of previous builds made this public test a success. 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 … The design was based on another driver's visor, but was taller than the original. 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. 7. In any case, the goal is always to minimize cost and maximize pr… Our website uses cookies. As its name implies, additive manufacturing adds material to create an object. Support structures are expensive to print and remove, considering they have to be subtracted from the final part. 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. He is the engineering leader GE Additive, the newest business unit at GE, a unit that indicates AM’s disruption with its very existence. 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. Abstract. The best approach is to create designs that have minimal support structures. One of these applications was the 3D printing of very thin "egg shell" molds for silicon casting. Platform. Event Board A bracket redesign has a lot to say about the successful application of metal AM. Evan Kuester, applications engineer for 3D Systems, showcased multiple examples of parts made using selective laser sintering (SLS) in his talk. Otherwise the down-facing surface quality can be very poor. Specifics are specialized. 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. 9. In additive manufacturing, there are very specific design rules and tools that will allow you to create an optimized design, ready for 3D printing. Click the play button to watch a short video on how ASME can help you harness design for additive manufacturing and overcome its challenges. However, in order to benefit from the inherrent opportunities of AM, it is necessary to quantify the fundamental attributes in comparison with traditional methods. 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. “If there are too many constraints, one may never arrive at an optimal solution. Home » 3D printing news » Expert Advice » How to Design for Additive Manufacturing: Experts give their advice! Altair provides design software that goes beyond the creation of unique prototypes and provides a robust simulation toolchain to support production designs. (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. Job Board 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. 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. 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. 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 unique characteristics of AM, such as gradient materials and micro-structures, have opened up a new direction in jet engine design and manufacturing. Last month I discussed how Design for Additive Manufacturing (DFAM) is the value multiplier when it comes to additive manufacturing (AM). Some are not a concern, others are a major concern. 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. 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. Designing for manufacturability comes after the initial mechanical and/or electrical design, but before the design is released to the supplier for fabrication. The goal, he says, was not to pull specific parts off the engine and 3D print them. How to optimize the design of an example part to save $500 in material costs, 80 hours of machine time, and manual labor time. In this course, we explore the basics of geometry creation and the mindset shift needed to build a generative design—a deeper understanding of generative design, its parameters, and how to work with the results specifically aimed at Hosted by SME as part of its Smart Manufacturing seminar series, the event took place in Knoxville, Tennessee. Image courtesy SME. 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. Work with our additive design team to adapt your design for best results in an industrial 3D printer. 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. Anatomic Models; D2P Software; Medical Device Design and Manufacturing; Medical Simulation; Point-of-Care Solutions; Virtual Surgical Planning; Dental. Book a Call. We asked three additive manufacturing experts for their opinion on the matter! Newer programs, such as generative design or topology optimization, help designers think about creating designs for additive manufacturing technologies. 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. Topology optimization is none other than a proven generative design method that is focused on optimizing material distribution using sound numerical methods. “There is a lot of collaboration when we start. (View the schedule and register for future events here.) Zwart highlighted the winner of the 2016 challenge, a ball check valve for a thermal test rig that was prone to leaking. 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 mandate to implement "design for additive manufacturing" (or neatly abbreviated: DFAM) is not as simple as designing a part to be built additively. The redesign eliminated the leaks by consolidating the valve's five parts into just one additive build. One must add a constraint to ensure that the structure that is generated has surfaces well over the 45-degree angle from the horizontal. In fact, both techniques are often associated. 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. The optimized shapes you get from topology optimization are very often impossible to manufacture using traditional processes. We asked three additive manufacturing experts for their opinion on the matter! A team from Altair leveraged simulation, topology optimization and 3D printing to design an optimized hip stem that meets both conditions. 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. Otherwise the down-facing surface quality can be very poor. 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! 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. One of the examples given in his talk was a visor custom-made for a race car driver. Form 3 | Formlabs The best approach is to create designs that have minimal support structures. This digital information can then be used to create a new component or directly optimize its design for Additive Manufacturing. 10. Finally, the results of these studies and analysis are incorporated into the design of … This concept emerges due to the enormous design freedom provided by AM technologies. 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. 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. By controlling these variables, it's possible to make topology optimization more productive for additive applications. The Constraints Have Changed. 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. This eLearning course focuses on all stages of production and manufacturing, including design, post processing, and business considerations. Take for example metal 3D printing, and more precisely Laser Powder Bed Fusion technology. Zwart answered that his team strives to look at failures as a learning experience. 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. Was this expert advice useful? One of the takeaways: Support structures are worth the effort! 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. 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. Mechanical post-processing removes the support structure, and finish/drill/mill holes etc. 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. Peter Rogers explains in more detail: “, For example, there is a strong focus on generative design and, You have most probably heard of topology optimization and generative design before. Instead, the team was challenged to `` set the architecture of design... 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