Design for Additive Manufacturing
Design for Additive Manufacturing (DfAM) is a specialized approach that focuses on creating product designs optimized for the capabilities and constraints of additive manufacturing technologies, such as 3D printing. Unlike traditional subtractive manufacturing methods, which involve removing material from a larger block, additive manufacturing builds up objects layer by layer from digital models. DfAM takes advantage of this layer-wise construction process to unlock new possibilities in design, allowing for intricate geometries, lightweight structures, and the integration of complex features that were previously challenging or impossible to achieve. Designers practicing DfAM consider factors like material efficiency, support structure minimization, and the reduction of post-processing requirements, ultimately aiming to harness the full potential of additive manufacturing for more efficient, innovative, and customized product development.
Additive manufacturing is not simply ‘another way to make the same product’. The fundamental approach to DfAM is different to that of other manufacturing methods and must be utilised to get the best value out of any additive manufactured product. Here are some ways DfAM can add value to your business:
How can NOVL use DfAM to help you?
By optimizing designs for additive manufacturing, it becomes possible to create lightweight structures without compromising strength or functionality. This is particularly valuable in industries such as aerospace and automotive, where weight reduction can lead to fuel efficiency and overall performance improvements. Take a look at Dan’s study on using generative design to optimise a CNC machined bracket here.
Reduced Product Weight
DfAM enables the creation of intricate and complex geometries that are challenging or impossible to achieve using traditional manufacturing methods. This allows for innovative designs and improved product performance. Examples of this include lattice structures, which can provide efficient material properties and even impact resistance, and irregular internal channels which can be optimised for cooling or heating applications. Check out Dan’s study on the performance and material properties of 3D printed lattices here.
Complex Geometries
Image credit: Autodesk
DfAM allows for more efficient use of materials. Traditional manufacturing processes often result in significant material waste, whereas additive manufacturing builds objects layer by layer, minimizing material consumption and reducing costs.
Efficient Material Usage
DfAM provides the ability to consolidate multiple components into integrated designs. Unlike traditional manufacturing that often involves assembling numerous parts, additive manufacturing allows for the creation of complex structures as a single, cohesive unit. This not only simplifies the assembly process but also enhances product reliability by minimizing potential points of failure. DfAM's capacity to streamline assembly contributes to more efficient manufacturing workflows and can lead to cost savings in labour and materials.
Reduced Part Count
Image credit: 3D Systems / all3dp.com
DfAM facilitates unparalleled customization by allowing designers to tailor products to specific needs and preferences. Through innovative design solutions, DfAM encourages a departure from traditional manufacturing constraints, empowering designers to explore novel forms and structures that were once impractical. This results in products that are not only highly personalized but also push the boundaries of conventional design, fostering innovation in various industries.
Innovative and Custom Designs
Image credit: 3D Systems / Metal-AM.com