Design for Additive Manufacturing

Design and Development of Innovative Products

Design for Additive Manufacturing (DfAM) is the key to creating a product that takes full advantage of the unique opportunities offered by AM.
At the same time, DfAM must take into account and respect the process constraints specific to the AM technology that will be used to produce the product. This goes beyond simply redesigning existing parts for AM. However, what is still difficult to achieve is to be successful to take advantage of the additional benefits that AM can bring to an entire product through improvements in shape, reliability, cost and performance. To do that requires knowing the benefits that AM can enable as well as its Drawbacks and Limitations.

Design for AM is definitely more of a concept method in which conscious decisions are made, often compromises, rather than faithfully following a set of design rules as in the case of traditional technologies.

We can Design for You

In-depth knowledge of additive processes and technologies, thanks to 10+ years of experience in this field allow us to understand and identify the design rationale that includes the deep knowledge of what is called “DRIVERS” of technology.
These include maximizing lightness, consolidating multiple parts, maximizing customization, or improving performance. Each one of these “DRIVERS” allows you to identify the component and the goal you want to achieve through the use of the AM. Likewise, it is of equal importance to understand the drawbacks & limitations of each technology in order to be able to select the correct process and the best AM technology for each type of project.

Concepts such as machine access and availability, process interpolation, production capabilities, and scalability of each technology are necessary to be able to guide such a choice.

Guidelines, Feature level rules that are dependent and independent of each technology, and 3DPrinting rules are the basis for being able to properly design and produce a component. These gather considerations for each application and function of the case study, material requirements, accuracy and surface finish, tolerances and process characteristics of each technology.

This allows, for example, the reduction in the number of support structures when required, and this immediately translates into lower post-process costs. Improved 3Dprintability of the part reduces time on the machine or allows the mechanical property of the component to be optimized, this is possible by selecting the correct orientation on the machine and better filling of the build volume.

These are just some critical points of the AM process, which thanks to our Know-how we can overcome and optimize. In fact, from the first stage of prototyping to the final component, the deep knowledge and manipulation of these design lines allow us to design by exploiting the maximum potential that Additive technologies unlock.

The entire knowledge of prowess for AM: also known as DfAM enables in its entirety a perfect understanding and management of all phases of the product. Designing for additive manufacturing requires an understanding of the design freedoms and limitations of the technological process, as well as the effect of the choices made regarding the setup and post-processing of the component that will affect its final performance characteristics. The AM designer must consider factors such as build volume limitations, self-supporting features, powder and support removal, and surface finish requirements. Qualified engineers and figures and appropriate software tools are needed for the 3D modelling of potentially very complicated structures (e.g., bionic design, lattice structures, conformal channels, etc.).

We offer guided design services throughout the development and evolution of the idea up to the final prototype using all the experience gained over the last 10 years in contact with the world of AM.

Additive Design

Bionic Desing

Lattice Structures

 

Conformal channels

 

Topology Optimization

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