Design for Additive Manufacturing

• • Design for Additive Manufacturing (DfAM) - is the methodology of incorporating real-world manufacturing constraints, capabilities, and considerations when engineering components which will be additively manufactured.

  • There are general DfAM concepts that apply universally—such as minimizing support material, consolidating assemblies, optimizing internal structures (like lattices), and designing for part orientation—but on the same token, each individual AM process has its own, distinct DfAM characteristics. For example:

    • Material Extrusion (e.g., FDM/FFF) has design constraints such as overhang angles (typically limited to 45° without support), print orientation and resulting layer adhesion, minimum wall thickness, and support removal accessibility. Sharp overhangs and fine internal features may pose issues.

    • Vat Photopolymerization (e.g., SLA, DLP) enables high-resolution features and smooth surface finishes but requires attention to resin drainage, part orientation to avoid suction forces during peeling (cupping), and adequate support placement for fine details. Hollow parts must include drain holes.

    • Powder Bed Fusion (e.g., SLS, SLM, DMLS) offers significant design freedom, including the ability to produce complex internal geometries and consolidated assemblies without the need for support structures (in the case of SLS). However, thermal stresses, powder removal from internal channels, minimum feature sizes, and surface roughness must be considered.

Overall, AM has the potential to improve both the manufacturability of designs as well as the performance, for several reasons:

• Design Freedom: AM allows for the creation of complex geometries that would be difficult or impossible to achieve with traditional manufacturing processes. This can lead to improved product performance and functionality, as parts can be optimized for specific applications.

• Reduced Design Limitations: Traditional manufacturing processes often require certain design features to be modified or eliminated due to limitations in tooling or production processes. AM, on the other hand, has fewer design limitations and can produce parts with more intricate and complex geometries.

• Faster Product Development: AM enables rapid prototyping, which can speed up product development cycles. This can allow designers to quickly iterate on their designs, test new concepts, and bring products to market faster.

• Lower Tooling Costs: Traditional manufacturing processes often require expensive tooling to be designed and manufactured. With AM, no tooling is required, which can significantly reduce production costs.

• Improved Supply Chain Efficiency: AM can reduce the need for extensive supply chains by producing parts in-house. This can help manufacturers to streamline their supply chain and reduce lead times.

• Lightweight Parts: AM enables the creation of lightweight parts by using only the amount of material required to produce a part. This can lead to improved performance and efficiency, particularly in industries such as aerospace and automotive.

• Improved Part Strength: AM can produce parts with improved strength and durability due to the layer-by-layer approach used in the manufacturing process. This can lead to improved product performance and longer part lifetimes.

• Customization: AM enables the production of customized parts and products, which can meet the unique needs of individual customers. This can lead to improved customer satisfaction and loyalty.

• Distributed Manufacturing is a decentralized approach to production that involves the use of multiple, geographically local facilities and resources to produce goods, rather than relying on a singular, geographically distant, centralized manufacturing facility. This approach is enabled by advances in digital technologies (Industry 4.0), of which AM plays a key role.

• AM plays a key role in enabling distributed manufacturing by making it possible to produce parts and products locally, on-demand. This reduces the need for large, centralized manufacturing facilities and enables companies to produce goods closer to their end customers. AM also enables greater design flexibility and customization, making it possible to produce products that are tailored to specific customer needs.

  • The pros of distributed manufacturing enabled by AM include:

    • Reduced transportation costs and carbon emissions

    • Faster response times to changes in demand and production requirements

    • Greater flexibility in terms of customization and personalization of products per individual consumer/customer

    • Reduced risks associated with supply chain disruptions by providing local production capabilities.

  • However, there are also some cons to distributed manufacturing enabled by AM:

    • The cost of AM technology and materials can be high, making it difficult for small businesses and individuals to participate in distributed manufacturing.

    • Quality control and standardization can be more difficult in distributed manufacturing, as each local facility may have different equipment, processes, and capabilities.

    • Lack of economies of scale in distributed manufacturing can make it more expensive for large-scale production runs.

• Overall, distributed manufacturing enabled by AM has the potential to provide significant benefits in terms of cost savings, sustainability, and flexibility. However, careful consideration of the costs and benefits is necessary to determine whether distributed manufacturing is the best approach for a particular product or industry.