Design freedom - Additive

manufacturing
 Shape Material Hierarchical Functional
complexity complexity complexity complexity
 Shape complexity

It is possible to manufacture virtually any shape,

which means that customized geometries are
achieved readily and shape optimization is
enabled.
 Material complexity

Material can be processed one point, or one

layer, at a time, enabling the manufacture of
parts with complex material compositions and
designed property gradients.
 Hierarchical complexity
Hierarchical multi-scale structures can be
designed and fabricated from the
microstructure through geometric
mesostructure (0.1~10mm) to the part-scale
macrostructure. Basic idea of hierarchical
structures is that features at one size scale can
have smaller features added to them, and each
of those smaller features can have smaller
features added
 Functional complexity
Fully functional assemblies and mechanisms
can be fabricated right away. When building
parts in an additive manner, the inside of the
part is always accessible. This makes it possible
to intensively integrate multiple design domains
to realize multi-functionalities.
Comparison graph
"Design vs Costs"

AM offers high level of complexity,

often denoted as “complexity for free”
when compared with what traditional
methods of manufacturing can
achieve.
Advanced features of Additive
manufacturing
Functional Structure
integration optimization
 Functional integration

Additive manufacturing makes it possible to

integrate functions in parts. ie., fewer assembly
components, less logistical effort and greater
flexibility.
Applications range from mechanical functions
like integration of moving parts or
thermodynamic functions, for example cooling
channels or incorporation of electric circuits for
electrical functionalization.
 Structure optimization

Structure optimization is an optimization method

that employs mathematical/software tools to
optimize material distribution in a part to be
designed.
Parts designed using structure optimization use
less material to achieve the same or better
results, translating to direct cost savings and an
improved product.
Impacts of Additive manufacturing on
DFM, DFA, DFP
 Design simply
Conventional Design
Design for the ease of fabrication
Methodology(DTM)
Design for the ease of assembly

Minimize material types in an assembly

Standardize components
 Do not consider conventional design methods

AM enabled design Design Complex

Feel free to use freeform design/parametric design

Reduce number of assembly parts by functional integration

Optimize your design towards highest strength and lowest weight

Do not think about tooling because they are no longer needed

 Design for Manufacturing (DFM)

The layer-by-layer working mechanism and direct fabrication from CAD model totally expands designers’
imagination in part design. Unlike the subtractive and formative processes, this additive process can virtually
build parts with any shapes.

Parts could advantageously be designed from the modular and hybrid point of view, whereby parts are seen
as 3D puzzles with modules.

Materials with AM technologies can be processed at each point or at each layer at a time, the manufacturing
of parts with complex material compositions and designed property gradients is enabled. For example,
heterogeneous structure can be achieved by differentiating structure density with respect to load conditions.

AM process enables the fabrication of architecture design of hierarchical complexity across several orders of
magnitude in length scale.

The unique process characteristics of AM make it possible to remanufacture and repair with low cost and
relative high speed.
 Design for Assembly (DFA)

AM facilitates integrated assembly and embedded components because of

layer-by-layer or point-by-point characteristics.

Joining multiple materials together by AM is a feasible assembly method. The

use of multiple materials within AM to increase part functionalities.
 Design for Performance (DFP)

Traditionally, product with simple geometry is desired despite of sacrificing its function or
performance. The ability of AM to produce highly flexible and functionally integrated parts
fosters the idea to create smart parts that quickly adapt and response to the operation
environment.

AM-enabled design could be optimized for other better performance, such as weight
reduction, better heat dispersion, and less stress concentration by means of
heterogeneous structures.
Design for Additive Manufacturing
(DFAM)
 Definition

Design for Additive Manufacturing (DfAM) is the

art, science and skill to design for
manufacturability using 3D printers. Different
from traditional manufacturing, this additive
design process empowers engineers to create
more intricate shapes and production parts
while reducing weight and material
consumption.
AM software for design

Creo

Solidworks

Rhino

Fusion 360

Materialise 3-matic

nTopology’s nTop Platform

Autodesk's Netfabb Ultimate

References
- https://www.farinia.com/blog/design-additive-manufacturing-evolution-design-support-breakthrough-
manufacturing

- Shang yang, et al, "Additive Manufacturing Enabled Design Theory and Methodology: A Review".

- https://www.fastradius.com/resources/topology-optimization-advantages/

- https://all3dp.com/1/top-design-for-additive-manufacturing-dfam-software/
Thank you!
S.Aravind prasad
Contact : 9566235878
Mail id: aravind.prasad19@gmail.com