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Preferred Partner in Metal 3D Printing

Design for Additive Manufacturing (DfAM)

DfAM – is the process of creating the design of a part that is most suitable for Additive manufacturing.
It is a method that guides designers through structured, step by step design process for developing AM products.
Helps designers find possible solutions for product functions, suggest ideas to enhance, stimulate their creativity to find innovations, remove cognitive barriers & subconscious limitations in design.

Generally products were Designed for Manufacturing and Assembly (DfMA), onset of AM has changed that, Conventional manufacturing constraints do not restrict product design anymore;
‘Design for Additive Manufacturing’ (DfAM) puts the emphasis back on functionality & efficiency of the part.

The main objectives of DfAM at product conceptualization stage is to,

  •  Reimagine a part‘s physical representation
  •  Form Driven by Function
  •  Incorporate AM features in design
  •  Maximize product life cycle efficiency

Design

  • CAD Modelling 3D Modelling | Virtual Prototyping |Surface Modelling
  • Structural Analysis Stress – Strain Analysis | Strctural Optimisation | Finite Element Analysis
  • Flow Analysis Fluid Flow Simulation | Parametric Study | Turbulant Flow Analysis

DFAM

  • BIO – MIMICRY GENERATION
  • DESIGN TOPOLOGY
  • OPTIMIZATION
  • ASSEMBLY SIMPLIFICATION
  • LATTICE STRCTURES

Design for Additive Manufacturing

Vortex tube

  • Part consolidation from multiple parts to single part.
  • Lower Mass production
  • Low manufacturing cost

Vortex tube

Case Study: Hydraulic Manifold 

Additive-Hydraulic-Manifold-Design

  • Improved Performance
  • Mass reduction by 75%
  • The lifecycle for the manifold block was reduced to 8 hours against conventional method of 30 hours.
  • Improved flow efficiency up to 55%

Hydraulic-Manifold-Comparision

Case Study: Automotive Brackets

Additive-Automotive-Bracket

  • Weight reduction by 70%
    • with lighter structure and increased material efficiency
  • Minimizing 18% of stress
    • Achieved Stiffer Structure
  • Deflection was reduced by 28%
    • Structural integrity was improved
  • Reduced lead time and costs
  • Shorter Design Cycle
  • Economical production

Automotive Bracket Comparison

Case Study: Toggler 

Additive Toggler

  • Weight reduction by 45%
  • Material saving by 38%
  • Lead time reduction by 6H

Toggler - comparison

Case Study: Rectifier Heat Sink

  • Customer Weight Limitation for the Heat Sink <= 200g
  • Optimized Weight of Heat Sink = 92 grams
  • Optimized Volume = 3.4456*10^-5 m3
  • Max allowable Junction Temperature = 150 °C
  • Optimized Junction Temperature = 130 °C

Case Study: TPMS Oil Cooler (Heat Exchanger)

TPMS Heat Exchanger

  • Thermal efficiency by 80 % increase

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