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[Article]

Design for Additive


Manufacturing
p.02 Article / Design for Additive Manufacturing www.desktopmetal.com

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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.

By ensuring parts are easy to produce, designers and engineers


have reduced manufacturing costs for thousands of products,
resulting in both lower prices for consumers and higher margins
for manufacturers.

The emergence of metal and composite 3D printing has brought with


it a new design language - Design for Additive Manufacturing (DfAM)
- developed to allow manufacturers take advantage of the enormous
design freedom that comes with 3D printing.

This is the first in a seven-part series examining how the


principles of DfAM upend many of the long-standing rules around
manufacturability - allowing engineers and designers to place a
part’s function at the center of their design considerations.

Among the benefits of additive manufacturing this series will


explore are:

• Complex geometry
• Generative design
• Tooling-free manufacturing
• Assembly consolidation
• Internal features and channels
• Fine features
• Lightweighting

This is how DfAM is rewriting the rules of manufacturing design and


creating next-generation parts and products.

© 2021 Desktop Metal, Inc. — All Rights Reserved.


p.03 Article / Design for Additive Manufacturing www.desktopmetal.com

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.

© 2021 Desktop Metal, Inc. — All Rights Reserved.


p.04 Article / Design for Additive Manufacturing www.desktopmetal.com

01
Complex
Geometry

Part Example:
EWOL Propeller Pinion

Located in Milan, Italy, EWOL is a leading vendor of high-tech marine


propellers for sailing yachts.

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.

Originally produced via investment casting, EWOL had to place


orders for at least 100 of the parts to justify the cost of casting.
This was prohibitively large for a highly-customized, low-volume
part. Casting lead times were also quite long, due to the many
manufacturing steps involved, and parts still required challenging
and expensive machining before a pinion could be delivered to
the customer.

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.

© 2021 Desktop Metal, Inc. — All Rights Reserved.


p.05 Article / Design for Additive Manufacturing www.desktopmetal.com

01
Complex
Geometry

Part Example:
Sensor Holder

This part is used to hold multiple sensors while measurements are


taken in a running machine.

The intricate small geometry of this sensor holder [Fig. 02] makes
the part an ideal candidate for printing on the Shop System™.

Since this part was never produced in large numbers, redesigning


it for a mass manufacturing method like investment casting or metal
injection molding was impractical. By printing it, however, the team
was able to manufacture the part with an extreme reduction in both
manufacturing lead time and part cost.

Printing on the Shop System also allows for manufacturing flexibility


- when the design needs to be modified to incorporate different
sensors, engineers can simply send a revised file to the printer and
have hundreds of sensor holders in their hands that same week.

© 2021 Desktop Metal, Inc. — All Rights Reserved.


p.06 Article / Design for Additive Manufacturing www.desktopmetal.com

01
Complex
Geometry

Part Example:
Power Steering Joint

This joint [Fig. 03] is designed to transfer power from an electric


motor to the steering wheel in an electric power steering system. The
part features intricate spline teeth that are used to connect the join
to the electric motor, these teeth generally require extensive post
processing after the rest of the part is machined, but with binder
jetting the teeth can be printed with the rest of the part extremely
easily. This greatly simplifies fabrication of this complex part.

© 2021 Desktop Metal, Inc. — All Rights Reserved.


p.07 Article / Design for Additive Manufacturing www.desktopmetal.com

01
Complex
Geometry

Product Innovation Example:


Custom Bolt

This custom-designed bolt [Fig. 04] is used in specific applications


where an off the shelf fastener wouldn’t suffice. Due to the high cost
of hard tooling, most bolts are manufactured in quantities of millions.
For this bolt, however, only a few tens of thousands were needed.
This part features complex lightweighting features as well as the
thread. Threading the bolt would generally be a secondary rolling or
tapping operation but with binder jetting the working thread can be
printed right into the part. Printing on the Production System also
allows this bolt to be produced with no tooling required, allowing for
a dramatically reduced cost per part.

© 2021 Desktop Metal, Inc. — All Rights Reserved.


p.08 Article / Design for Additive Manufacturing www.desktopmetal.com

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).

Developed to take advantage of the enormous design freedom that


comes with 3D printing, DfAM allows manufacturers unlock a host of
benefits - from highly complex geometry to assembly consolidation
to the use of generative design tools - and create parts that
would otherwise be too difficult or costly to justify with traditional
manufacturing methods.

Arguably the most extreme example of the geometric complexity


made possible with 3D printing, generative design uses software
tools to create highly-optimized parts backed by complex
computational simulations.

Built to withstand specific loads and designed according to user-


defined constraints, generative parts only put material where it’s
needed, resulting in parts that are as much as 50 percent lighter - yet
equally strong - than conventional designs.

Creating the complex geometry of generative parts via traditional


methods would not only be difficult - if not impossible - but would
also be wildly expensive and time-consuming, making additive
technology the only way to access this new design space.

© 2021 Desktop Metal, Inc. — All Rights Reserved.


p.09 Article / Design for Additive Manufacturing www.desktopmetal.com

02
Generative
Design

Part Example:
Cifarelli Shaker Hook

Located in Milan, Italy, EWOL is a leading vendor of high-tech marine


propellers for sailing yachts.

A leading vendor of agriculture and gardening equipment, Cifarelli is


located in Voghera, Italy.

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.

Though generally produced in lots of approximately 1,000 via


aluminum chill casting, Cifarelli does have the need for low-volume
production of shaker hooks for specific customers, fruits, and
regions. Due to the cost of investing in tooling, however, custom
shaker hooks cannot economically be produced in low volumes.

Seeking a more economical production method for low-volume,


custom shaker hooks, Cifarelli turned to the Desktop Metal Studio
System™. Since the part would be printed in steel, Cifarelli redesigned
it to ensure it was no heavier than the original aluminum component,
as low weight is essential to reducing strain on the motor.

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.

© 2021 Desktop Metal, Inc. — All Rights Reserved.


p.10 Article / Design for Additive Manufacturing www.desktopmetal.com

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.

To create custom mounts, Turner engineers first scanned the original


mounts, then loaded the scans into Live Parts™, a generative design
software package designed by Desktop Metal.

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.

Turner engineers then applied loading scenarios to the model, and


the part “grew” into an optimized engine mount that mimics organic
shapes found in nature. The end result is an optimized, lightweight
part that fits the space perfectly, and could be produced in months
less time than traditional manufacturing methods like casting
or machining.

© 2021 Desktop Metal, Inc. — All Rights Reserved.


p.11 Article / Design for Additive Manufacturing www.desktopmetal.com

02
Generative
Design

Product Innovation Example:


Skateboard Truck

This skateboard truck was redesigned from the original cast


component to be printed on the Desktop Metal Shop System.
Generative design allowed for the part to be significantly
lightweighted while actually adding part strength, since the
material changed from Aluminum to Steel.

© 2021 Desktop Metal, Inc. — All Rights Reserved.


p.12 Article / Design for Additive Manufacturing www.desktopmetal.com

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.

If needed, designers can print multiple versions of a part, then


quickly iterate on the design based on functional testing results.
The speed and accessibility of additive manufacturing allows design
teams to go through dozens of design iterations in as little as a week.

Once part designs are finalized, binder jetting technology makes it


easy to go from printing one-off, low volume prototypes to producing
thousands or even up to millions of parts.

Because there is no need for tooling or complex set-ups,


manufacturers can produce a part one day, and switch to a new part
the next, with no delay in production.

Additive technology also enables DfAM principles by eliminating the


need for hard tooling.

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. If needed, designers can print multiple versions of a part, then
quickly iterate on the design based on functional testing results.
The speed and accessibility of additive manufacturing allows design
teams to go through dozens of design iterations in as little as a week.

Once part designs are finalized, binder jetting technology makes it


easy to go from printing one-off, low volume prototypes to producing
thousands or even up to millions of parts.

Because there is no need for tooling or complex set-ups,


manufacturers can produce a part one day, and switch to a new part
the next, with no delay in production.

© 2021 Desktop Metal, Inc. — All Rights Reserved.


p.13 Article / Design for Additive Manufacturing www.desktopmetal.com

03
Tooling-free
Manufacturing

Part Example:
Seat Belt Pulley

This output pulley is an essential component of the retracting


mechanism in a car seat belt.

This part features an undercut radial groove that, without printing,


would require advanced sliders during the press-and-sinter process.
Printing this part with the Shop System™ eliminates the huge cost
and complexities associated with press and sinter.

Depending on the model of car, different models of this pulley may


be needed. By eliminating the need for tooling, 3D printing allows
manufacturers to easily switch between designs - one model can be
printed overnight, and a different design printed the very next day,
with virtually no delay or setup time.

© 2021 Desktop Metal, Inc. — All Rights Reserved.


p.14 Article / Design for Additive Manufacturing www.desktopmetal.com

03
Tooling-free
Manufacturing

Part Example:
Bulb Nozzle

This part is a custom spray nozzle used in chemical processing.

Though normally cast, followed by extensive secondary machining


operations, this part needed to be produced in quantities of
approximately 300, making it an ideal fit for the Shop System™. By
printing the nozzles, the entire order could be produced in less than
a week, and required just one secondary threat-tapping operation.

Depending on the chemical operation, different spray geometries


may be required - since 3D printing eliminates the need for tooling
the nozzle can be changed on demand and printed to conform to
each process.

© 2021 Desktop Metal, Inc. — All Rights Reserved.


p.15 Article / Design for Additive Manufacturing www.desktopmetal.com

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.

The complex, thin features in this part would make it a challenge


for machining and would require a very complex/ expensive metal
injection mold tool.

© 2021 Desktop Metal, Inc. — All Rights Reserved.


p.16 Article / Design for Additive Manufacturing www.desktopmetal.com

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).

Developed to take advantage of the enormous design freedom that


comes with 3D printing, DfAM allows manufacturers unlock a host
of benefits - from highly complex geometry to the use of generative
design tools to the ability to create internal features and channels
- and create parts that would otherwise be too difficult or costly to
justify with traditional manufacturing methods.

For some 3D printed parts, the greatest benefit isn’t on the outside,
but the ability to create complex internal features.

By building parts layer by layer, 3D printing opens new possibilities


for engineers and designers to create parts with internal features
- like conformal cooling channels - that would be impossible for
conventional manufacturing approaches.

Incorporating such features into parts can often result in improved


performance like faster cooling rates for injection molds and
improved heat transfer rates for heat exchangers, leading to
production increases as well reducing both the time and cost of
creating parts.

© 2021 Desktop Metal, Inc. — All Rights Reserved.


p.17 Article / Design for Additive Manufacturing www.desktopmetal.com

04
Internal Features
and Channels

Part Example:
Asthma Inhaler Mold Insert

This mold insert is used for plastic injection molding of the


mouthpiece on an asthma inhaler.

When injection molding a part, cooling often accounts for up to 95%


of the cycle time. Incorporating a conformal cooling channel that
closely follows the surface of the mold core significantly increases
the heat transfer rate, allowing the part to be cooled and ejected
faster, reducing mold cycle time by up to 40%.

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.

© 2021 Desktop Metal, Inc. — All Rights Reserved.


p.18 Article / Design for Additive Manufacturing www.desktopmetal.com

04
Internal Features
and Channels

Part Example:
Helical Heat Exchanger

This heat exchanger is used for continuously cooling fluids in a


chemical processing plant.

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.

This cooling channel substantially increases the part’s heat transfer


rate. External and internal fins - features that cost very little to print,
but would add significant cost if the part were machined - were also
added to increase heat transfer surface area. Printing the part in
copper allowed for excellent thermal conductivity through the heat
exchanger.

© 2021 Desktop Metal, Inc. — All Rights Reserved.


p.19 Article / Design for Additive Manufacturing www.desktopmetal.com

04
Internal Features
and Channels

Part Example:
Surgical Tool

This is a nozzle used during surgery; it is beneficial for it to be


customized for each patient. The part features an internal channel
that would require complex machining operations with multiple
fixturing setups; printing the part via binder jetting eliminates those
many machining steps, resulting in extensive cost savings. Similarly
since binder jetting does not rely on any tooling this part can easily
be customized for specific patients.

© 2021 Desktop Metal, Inc. — All Rights Reserved.


p.20 Article / Design for Additive Manufacturing www.desktopmetal.com

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.

This 3D printed atomizer features complex internal channels and


oblong shaped holes, which could not be manufactured with
traditional methods. These channels and oddly shaped holes allowed
for drastically better fuel mixing, leading to much better performance
as well as fuel savings.

© 2021 Desktop Metal, Inc. — All Rights Reserved.


p.21 Article / Design for Additive Manufacturing www.desktopmetal.com

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).

Developed to take advantage of the enormous design freedom that


comes with 3D printing, DfAM allows manufacturers unlock a host of
benefits - from highly complex geometry to assembly consolidation
to the creation of extremely fine features - and create parts that
would otherwise be too difficult or costly to justify with traditional
manufacturing methods.

Along with more complex features, metal 3D printing allows


engineers and designers to create parts with fine features that
would be too time consuming and expensive to justify creating via
conventional processes.

Machining very small features is notoriously difficult because parts


tend to chatter unless they are supported during cutting. Creating
specialized fixtures to support parts, however, is often too costly and
time-consuming to justify.

By allowing users to print those parts from metal, additive


manufacturing enables companies to create parts highly complex,
fine features without the need for fixturing or other tooling.

© 2021 Desktop Metal, Inc. — All Rights Reserved.


p.22 Article / Design for Additive Manufacturing www.desktopmetal.com

05
Fine Features

Part Example:
O-Ring End Effector

This small end effector is used to install an O-ring on a hydraulic


fitting.

Because only a few of these end-effectors were needed, the Studio


System™ was the ideal choice to produce them. Small, detailed parts
like these typically require expensive CNC machining and have long
lead times due to the difficult fixturing needed.

The Studio System’s high resolution (250μm) printhead,


manufacturers can print small parts with fine features which would
otherwise be difficult to machine.

© 2021 Desktop Metal, Inc. — All Rights Reserved.


p.23 Article / Design for Additive Manufacturing www.desktopmetal.com

05
Fine Features

Part Example:
Eyeglass Hinge

This is a live hinge for eyeglasses.

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.

© 2021 Desktop Metal, Inc. — All Rights Reserved.


p.24 Article / Design for Additive Manufacturing www.desktopmetal.com

05
Fine Features

Part Example:
Clipper Blade

This is a clipper blade for an electric hair trimmer. Manufacturing


this clipper blade would traditionally require expensive tooling for
production via stamping or metal injection molding. The fine features
on the teeth of the blade would require very expensive, precise
tooling. This would lead to high costs and long lead time on the tools.
Mass production on the Shop System eliminates tooling costs and
drastically reduces manufacturing lead time.

Furthermore, additive manufacturing enables mass customization -


allowing real-time adjustments to the part.

© 2021 Desktop Metal, Inc. — All Rights Reserved.


p.25 Article / Design for Additive Manufacturing www.desktopmetal.com

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.

Watch producers can now manufacture parts on-demand since


there’s no need to wait for tooling to be created, allowing for watch
designs that never could have been justified before.

© 2021 Desktop Metal, Inc. — All Rights Reserved.


p.26 Article / Design for Additive Manufacturing www.desktopmetal.com

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.

For most traditional manufacturing processes, lightweighting equals


increased cost, lead time and waste, but the additive nature of
3D-printed parts means lightweighting actually reduces waste, leading
to shorter processing times and lower part costs.

On the manufacturing floor, meanwhile, lightweight manufacturing


aids like end-of-arm tooling equals less wear-and-tear on machinery
motors and bearing, and less downtime for production lines.

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.

In addition to new features, additive manufacturing’s ability to


create complex geometry opens the door to lightweighting parts
through the use of lattice-like designs and closed-cell infill and
lightweighting features that normally couldn’t be justified with
traditional manufacturing.

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.

On the manufacturing floor, meanwhile, lightweight manufacturing


aids like end-of-arm tooling equals less wear-and-tear on machinery
motors, bearings, etc and less downtime for production lines.

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.

© 2021 Desktop Metal, Inc. — All Rights Reserved.


p.27 Article / Design for Additive Manufacturing www.desktopmetal.com

06
Lightweighting

Part Example:
APG End of Arm Tool

This end of arm tooling is used to hold a camshaft during an induction


heat treatment process.

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.

Machining those coring features would add significantly increase


both cost and manufacturing lead time - more cuts equal more
material removal and longer machining time.

With 3D printing, those features actually reduce part cost and


manufacturing lead time. Parts that are lightweight print and debind
faster, and use less material resulting in a less expensive part.
Printing end of arm tools allows APG to significantly reduce part cost,
manufacturing lead time, and incorporate light weighting features.

© 2021 Desktop Metal, Inc. — All Rights Reserved.


p.28 Article / Design for Additive Manufacturing www.desktopmetal.com

06
Lightweighting

Part Example:
Support Plate

When off-the-shelf spacer options proved inadequate, the designer


of this support plate looked to utilize the Shop System™ for its speed
and low per-part cost.

Since weight is a critical factor in the design, printing this support


plate allowed designers to remove most of the weight from this part
while still leveraging the strength of steel to provide the needed part
strength.

By adding lightweighting features like the cutouts in this part, 3D


printing can lower part costs by reducing material usage.

© 2021 Desktop Metal, Inc. — All Rights Reserved.


p.29 Article / Design for Additive Manufacturing www.desktopmetal.com

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.

The design of this part is based on an assembly built from an


aluminum extrusion, two screwed-on end plates and a clamp collar.
The extruded part also requires extensive machining after extrusion.

By redesigning the part, Egar engineers were able to consolidate the


entire assembly into just one piece. This also significantly reduced
the weight of the part, allowing the servo motors to run faster,
leading to an improved manufacturing environment.

© 2021 Desktop Metal, Inc. — All Rights Reserved.


p.30 Article / Design for Additive Manufacturing www.desktopmetal.com

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).

Developed to take advantage of the enormous design freedom that


comes with 3D printing, DfAM allows manufacturers unlock a host
of benefits - from highly complex geometry to the use of generative
design tools to assembly consolidation - and create parts that
would otherwise be too difficult or costly to justify with traditional
manufacturing methods.

The ability to create complex new geometry, combined with the


additive nature of 3D printing, also opens the door to using DfAM
principles to explore assembly consolidation, or the combining of
several parts into fewer, multi-functional assemblies.

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.

Other benefits of consolidating multiple parts include saving money


by reducing waste, lightweighting of parts by eliminating the need
for screws and other fasteners, and simplified bill of materials and
assembly procedures.

© 2021 Desktop Metal, Inc. — All Rights Reserved.


p.31 Article / Design for Additive Manufacturing www.desktopmetal.com

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.

Traditionally, this part is made by cutting the threads on a lathe - a


challenging and time consuming process. Once finished, the gears
on either end of the screw are assembled with set screws and
adhesive.

Printing this part, however, allowed the assembly to be consolidated


into a single part, which can be produced faster and more affordable
than traditional machining.

This part was prototyped for functional testing using the Studio
System™ before being produced in higher volume using the
Shop System™.

© 2021 Desktop Metal, Inc. — All Rights Reserved.


p.32 Article / Design for Additive Manufacturing www.desktopmetal.com

07
Assembly
Consolidation

Part Example:
Connector

This is a fluid connector used in chemical processing.

This part features complex geometry and an internal channel that


would make it impossible to manufacture as a single component via
traditional manufacturing methods.

Printing this part, however, is easy, and results in a higher


performance part than the traditionally-manufactured assembly, while
simultaneously reducing part cost and manufacturing lead time.

© 2021 Desktop Metal, Inc. — All Rights Reserved.


p.33 Article / Design for Additive Manufacturing www.desktopmetal.com

07
Assembly
Consolidation

Part Example:
Crankshaft Starter Gear

This gear connects the crankshaft to the generator and water pump
in a motorcycle engine.

Manufacturing this part via traditional methods would require casting


followed by broaching operations to form the gear teeth.

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.

© 2021 Desktop Metal, Inc. — All Rights Reserved.

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