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A Guide To Designing For Metal 3d Printing
A Guide To Designing For Metal 3d Printing
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Introduction
Introduction
For decades, manufacturability has been among the most important
considerations - in some ways even more critical than form and
function - in the design of metal and composite parts.
• Complex geometry
• Generative design
• Tooling-free manufacturing
• Assembly consolidation
• Internal features and channels
• Fine features
• Lightweighting
01
01
Complex
Geometry
Complex geometry
Among the chief benefits DfAM brings to engineers and designers
is the ability to produce parts with far greater complexity than
traditional methods.
Because it’s not subject to the same limits that apply to traditional
manufacturing, additive manufacturing allows designers and
engineers to access a vast new design space.
The end result, however, isn’t designs that are simply more complex,
but that are often better. The ability to create highly complex parts
means designers can create parts that are optimized for their precise
application, not for manufacturability, resulting in parts that perform
better than their traditionally-manufactured counterparts.
And because the cost of printed parts does not scale with
complexity, manufacturers can keep costs low, making it far more
economical to produce complex, highly-optimized parts for
different applications.
01
Complex
Geometry
Part Example:
EWOL Propeller Pinion
This part is a propeller pinion [Fig. 01], used to connect the propeller
shaft to the propeller blades. EWOL, however, faced significant
challenges around its manufacture.
Using the Studio System™, EWOL was able to greatly simplify the
manufacturing process. By bringing the fabrication process in-
house, EWOL can be much more responsive to customer demands
because they no longer have to worry about minimum lot sizes. The
company was also able to reduce manufacturing lead time, lower
the part cost, improve the part quality, and substantially reduce the
amount of post-processing required.
01
Complex
Geometry
Part Example:
Sensor Holder
The intricate small geometry of this sensor holder [Fig. 02] makes
the part an ideal candidate for printing on the Shop System™.
01
Complex
Geometry
Part Example:
Power Steering Joint
01
Complex
Geometry
02
02
Generative
Design
Generative Design
Additive manufacturing is rapidly rewriting the rules of how metal
parts are made, and it’s doing it with the help of a new design
language - Design for Additive Manufacturing (DfAM).
02
Generative
Design
Part Example:
Cifarelli Shaker Hook
Shaker hooks are used in many parts of the world to vibrate tree
limbs, causing nuts, fruits, and vegetables to fall so they can be
harvested. This specific shaker hook is best for olives, harvesting
over 2,000 kg of olives per day, and can remove 95% of the fruit
without damaging the tree or its buds.
Created using generative design tools, the final design of the shaker
hook would be incredibly difficult, if not impossible, to manufacture,
but the additive nature of the Studio System™ made printing the part
easy for Cifafelli. The end result is a redesigned shaker hook which,
while weighing the same as aluminum shaker hooks, is far more
durable and optimized for its application.
02
Generative
Design
Part Example:
Turner Motorsports Engine Mount
Turner Motorsport is a BMW race team and auto shop for ultra high-
performance BMW cars.
Among the custom jobs Turner has taken on was an effort to marry a
modern V8 engine with a 2001 BMW M3 which is often cited as one
of the best handling sports cars of all time.
Many of the parts needed to combine the two, however, were not
compatible, forcing Turner engineers to create custom workarounds
to get the engine into the car. Among the components that had to be
replaced were the original motor mounts, which hold the engine in
the car’s frame.
Live Parts™ allows users to specify “keep out” zones, or areas where
the part geometry cannot go. In this situation the keep out zones
were essential to ensuring the new engine mounts didn’t interfere
with the mechanics of the rest of the car.
02
Generative
Design
03
03
Tooling-free
Manufacturing
Tooling free
Manufacturing
Without the need to manufacture jigs, fixtures or molds, engineers and
designers can go from design to functional part in as little as a day.
03
Tooling-free
Manufacturing
Part Example:
Seat Belt Pulley
03
Tooling-free
Manufacturing
Part Example:
Bulb Nozzle
03
Tooling-Free
Manufacturing
Part Example:
VVT Gear
This gear enables the engagement and shifting of all gears in a six
speed motorcycle transmission.
This part was able to be printed on the Shop system without the need
for tooling, this led to an increase in manufacturing lead time as well
as a reduction in part cost. Since no tooling was needed this part can
also be easily changed for different transmissions.
04
04
Internal Features
and Channels
Internal Features
and Channels
Additive manufacturing is rapidly rewriting the rules of how metal parts
are made, and it’s doing it with the help of a new design language -
Design for Additive Manufacturing (DfAM).
For some 3D printed parts, the greatest benefit isn’t on the outside,
but the ability to create complex internal features.
04
Internal Features
and Channels
Part Example:
Asthma Inhaler Mold Insert
Faster cycle times allow injection mold shops finish customer parts
faster, allowing them to quickly move on to new jobs and make
more money. Internal cooling channels like these are impossible to
manufacture via traditional methods but are very simple to print into
the part.
Due to the hard plastic that is being injected, this mold was printed
in H13 tool steel to give it significantly higher wear resistance. A very
difficult metal to machine, H13 can cause considerable tool wear and
very slow feed rate. Printing this part to near net shape allowed for
a 95% reduction in the CNC machining required - the only need was
to touch up critical surfaces and dimensions after sintering. This led
to a significant cost savings for this part, even when compared to a
version without the internal cooling channel.
04
Internal Features
and Channels
Part Example:
Helical Heat Exchanger
Since this part was intended for printing from the start, it could be
designed with its specific application in mind, rather than for easy
manufacturing. This meant printing the part with an internal helical
cooling channel - a feature that would be impossible to manufacture
via traditional methods.
04
Internal Features
and Channels
Part Example:
Surgical Tool
04
Internal Features
and Channels
Part Example:
UHT Atomizer
This fuel atomizer is used for mixing steam and fuel in a steam boiler
to power a liquid natural gas (LNG) tanker.
With the Studio System, the engineers were able to radically redesign
their conventional atomizers for significantly better performance.
05
05
Fine Features
Fine Features
Additive manufacturing is rapidly rewriting the rules of how metal parts
are made, and it’s doing it with the help of a new design language -
Design for Additive Manufacturing (DfAM).
05
Fine Features
Part Example:
O-Ring End Effector
05
Fine Features
Part Example:
Eyeglass Hinge
This part was able to combine two parts into one printed-in-place
assembly. This part features very fine details and needs to be highly
precise to allow the hinge to function properly.
05
Fine Features
Part Example:
Clipper Blade
05
Fine Features
Part Example:
Watch Case and Bezel
For each different watch model and size, different tooling is required
to produce the intricate fine features that are critical for holding
precision watch components. This makes doing smaller, more custom
watch models prohibitively expensive. The Shop system eliminates
the need for tooling leading to dramatically reduced part cost.
06
06
Lightweighting
Lightweighting
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.
Infill density and wall thickness can also be tuned to optimize part
performance by adding increased part strength or to provide additional
material to allow a part to be machined to critical tolerances.
While it means increased cost, lead time and waste for most
manufacturing processes, the additive nature of 3D-printed parts
means lightweighting reduces waste, leading to shorter processing
times and lower part costs.
Infill density and wall thickness can also be tuned to optimize part
performance by adding increased part strength or to provide additional
material to allow a part to be machined to critical tolerances.
06
Lightweighting
Part Example:
APG End of Arm Tool
The original part was machined from steel, but was so heavy it
caused excessive wear on the motors of the robotic arms holding
them. To ensure they could replace the end effectors quickly and
keep manufacturing lines up and running, APG turned to the Studio
System™ to add coring to the part, dramatically reducing its weight.
06
Lightweighting
Part Example:
Support Plate
06
Lightweighting
Part Example:
Egar Timing Belt Pulley
This timing belt pulley attaches to a servo motor, and is a key part of
the manufacturing environment at Egar Tool and Die.
07
07
Assembly
Consolidation
Assembly Consolidation
Additive manufacturing is rapidly rewriting the rules of how metal parts
are made, and it’s doing it with the help of a new design language -
Design for Additive Manufacturing (DfAM).
Because they are designed for their specific application, and not for
manufacturing ease, such consolidated assemblies often outperform
their conventional counterparts. Assembly consolidation can also
significantly increase production efficiency - manufacturing a single
part via 3D printing is faster and cheaper than producing several
different parts via traditional methods and fastening or welding them
together.
07
Assembly
Consolidation
Part Example:
Roller Screw
This roller screw is part of a linear actuator used to open and close
pilot valves in a steam power plant.
This part was prototyped for functional testing using the Studio
System™ before being produced in higher volume using the
Shop System™.
07
Assembly
Consolidation
Part Example:
Connector
07
Assembly
Consolidation
Part Example:
Crankshaft Starter Gear
This gear connects the crankshaft to the generator and water pump
in a motorcycle engine.
Using the Studio System, the final part was fabricated in just a few
days at a low per-part cost, allowing parts to be prototyped and
tested quickly before moving to a mass manufacturing method.