Preferred Partner in Metal 3D Printing
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
- Cost reduction due tolightweight construction.
- Reduced material usage due to structure optimization
- Design advantages: Freedom in the design process
- Univaled cannot be produced conventionally
Example : Hydraulic manifold
conventional block
Lean part for AM
Self supporting geometry modification
Advantages
- Reduction in Build time;
- Reduction in Material consumption;
- Reduced post processing & support removal
- Increased performance
Case study – Torsion arm (Machine tooling)
| Existing |
| Part Volume : 278017 mm3 |
| Support volume : 11228 mm3 |
| Build time : 15.2 H |
| Weight reduction: 52 % |
| Materia saving: 40 % |
| Lead time reduction : 8 H |
| Optimized |
| Part Volume : 130294 mm3 |
| Support volume : 4253 mm3 |
| Build time : 8.5 H |
Case study – Toggle lever (processing)
ExistingPart Volume : 138484 mm3Support volume : 7015 mm3Build time : 8.2 H
| Weight reduction: 45% |
| Materia saving: 38% |
| Lead time reduction : 6 H |
| Optimized |
| Part Volume : 81699 mm3 |
| Support volume : 30853 mm3 |
| Build time : 5.8 H |
Case study – Heat Exchanger
| Existing |
| Part Volume : 168372 mm3 |
| Support volume : 17015 mm3 |
| Conventional fabrication |
| Thermal efficiency : 80 % increase |
| Optimized |
| Part Volume : 182469 mm3 |
| Support volume : 3186 mm3 |
| Build time : 18 H |
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