How to Make the Most of Design for Additive Manufacturing (DfAM)
In the developing realm of additive manufacturing, creativity knows no bounds. However, to truly unlock the potential of 3D printing, understanding and applying Design for Additive Manufacturing (DfAM) principles is critical. DfAM goes beyond traditional design methods, utilizing the unique capabilities of additive manufacturing. In this blog post, we will dive into insights on how to make the most of DfAM principles and take your designs to new levels.
Embrace Complexity Without Hesitation
Traditional manufacturing methods often put a cap on the complexity of designs. With additive manufacturing, the sky is truly the limit. This level of freedom can be leveraged to design complex geometries, such as lattice structures, that would be impossible through conventional methods. This not only paves the way for innovation but can also lead to lighter and more efficient products.
Notably, the French automaker Bugatti harnessed 3D printing's design freedom for its latest Chiron supercar, crafting the world's most potent brake caliper from titanium.
This 3D-printed titanium caliper, while functioning like a typical one, boasts incredible strength and is approximately 40% lighter than the current aluminum version.
Photo Credit: Bugatti
Utilizing a metal 3D printing method known as Selective Laser Melting, the Bugatti team could explore diverse geometries and wall thicknesses that were previously unachievable using traditional manufacturing techniques. The outcome is a remarkably intricate brake caliper featuring wall thicknesses ranging from 1 mm to 4 mm.
Material Matters: It’s Time to Get Selective!
Additive manufacturing offers a plethora of materials – from plastics to metals and even Super Polymers. It’s crucial to be selective with materials to match the application. Being savvy with material selection can significantly impact the performance, weight, and cost of the final product. What’s more, additive manufacturing allows for material gradation within a single print, paving the way for multi-material products.
Additionally, Tronix3D stands out as one of only three facilities nationwide equipped with the Roboze ARGO 500, granting us the capability to print in Super Polymers such as Peek, CarbonPEEK, ULTEM™ AM9085F, Carbon PA PRO, Functional-Nylon, and Strong-ABS in our printing processes. This is particularly advantageous for the production of large formats in Super Polymers, offering a viable alternative to metals and saving costs.
Optimize for the Process: Master Your Printer’s Capabilities
DfAM is an art and knowing your tools is key. Each additive manufacturing process has its own set of capabilities and limitations. Mastering the specifics of the printer you are using is paramount. For instance, when using a powder bed fusion process, it’s wise to utilize self-supporting angles to reduce the need for support structures. This saves material and slashes post-processing time.
For example, Tronix3D offers a range of printing techniques, including HP Multijet Fusion (HPMJF), Fused Deposition Modeling (FDM), Stereolithography (SLA), and the latest addition of High Temp Super Polymers. Every method listed here has its benefits based on the individual requirements and desired outcomes of the specific project.
Integrated Assembly: Build with Purpose
One of the crowning glories of additive manufacturing is the ability to create assemblies as a single piece. This is the moment to build with purpose! By designing parts with an integrated assembly approach, we can sidestep joining processes and fasteners. One of the numerous advantages of additive manufacturing is the ability to merge multiple traditionally machined components into a single 3D printed part, as demonstrated by this scaled electric bike hub from our Tronix3D Product Design Gallery. Additionally, the incorporation of a belt drive pulley in this design helped reduce assembly expenses.
By leveraging your existing components or concepts, we possess the capability to reconfigure them for improved efficiency, ultimately resulting in more robust products, shorter assembly times, and trimmed costs for clients.
Sustainability in Focus
Additive manufacturing naturally produces less waste than traditional methods. But why not take it to the next level? Design parts with material conservation at the heart. Tactics such as hollowing out solid sections or using lattice structures can minimize material usage, save on costs, and bolster sustainability efforts.
Complementing our additive manufacturing expertise, Tronix3D provides access to an experienced manufacturing design team. We have successfully assisted numerous companies in not only translating their designs into reality but also enhancing them to guarantee effectiveness, structural integrity, and sustainability in the real-world market. In addition to optimization services, we can help our customers significantly reduce substantial production expenses that are usually associated with traditional tooling approaches.
Iterative Design: Prototype, Refine, Repeat
Iteration is the heart and soul of the design process. Rapid prototyping represents one of the foremost advantages of additive manufacturing compared to conventional methods. The capacity to swiftly iterate on designs enables teams to enhance and perfect products based on real-world performance rather than solely relying on predictions. This cycle is central to DfAM and is the golden key to achieving prime designs.
For example, Brightwake, a leading medical company, recently partnered with a 3D printing firm to create a complex blood recycling machine. Additive manufacturing was pivotal in identifying the most effective internal components for the machine, streamlining the product development process, and enabling a swift launch.
According to Brightwake's Research Director Steve Cotton, additive manufacturing delivered significant time and cost savings, reducing development expenses by approximately 96%. This would allow them to lower unit prices by $1,000 while maintaining their profit margin.
Stratasys 3D printed Saline Probe, produced from ABS Plus material, used to pierce a saline bottle and prime the Hemosep bag prior to use (PRNewsFoto/Stratasys Ltd.)
Crafting the Future: DfAM as the Springboard to Innovation
In conclusion, wielding Design for Additive Manufacturing principles is the “secret ingredient” to harnessing the full might of 3D printing. By welcoming complexity, getting picky with materials, honing in on printer capabilities, integrating assemblies, keeping sustainability central, and embracing iterative design, designers, and engineers can break through barriers and redefine what's possible. The realm of additive manufacturing is a treasure trove of opportunities for those bold enough to seize them.
About Tronix3D
Tronix3D is a leading contract-based Additive Manufacturing company dedicated to providing exceptional low-volume production and prototype parts for a diverse range of industries. Our comprehensive services encompass mechanical design and consulting, specifically tailored to the unique requirements of additive manufacturing. Leveraging cutting-edge printing technologies such as HP Multijet Fusion (HPMJF), Fused Deposition Modeling (FDM), and Stereolithography (SLA), we deliver high-quality, precision-engineered solutions for our valued clients in the robotics, energy, medical, and defense sectors. At Tronix3D, we pride ourselves on our commitment to innovation, quality, and customer satisfaction, ensuring that our partners receive the best possible results for their projects. Discover more about our services and capabilities at www.tronix3d.com.
