Design for AM

Question 1

What are the 3 types of manufacturing?

Answer 1

Additive
Subtractive
Formative

Question 2

What are the design benefits of AM?

Answer 2

Shape complexity
Functional complexity (can integrate features such as springs)
Material complexity (lightweighting, functional grading, 4D printing, lattice and auxetic structures)
Manufacturing without a tool
Personalisation and customisation
Iterative design
Part consolidation/ reduced assembly

Question 3

Key benefits of AM

Answer 3

Less assembly 
Reduced weight and height
Improved performance (fluid flow)
Minimised leak points
More reliable and robust design 
Design based on simulation

Question 4

Disadvantages of AM

Answer 4

Standard components (modular)
Limited surface finish
long design time
Reliability?

Question 5

How do you reduce part volume without compromising function?

Answer 5

Minimise size
Minimise height
Minimise external surfaces
Minimise empty volumes
Minimise internal infill
Minimise supports

Question 6

How do you eliminate the need for supports in a circle cutout?

Answer 6

Change to a diamond or teardrop

Question 7

What is the general rule of thumb for overhang angles?

Answer 7

Once past 45 degrees, support structures will be required

Question 8

Disadvantages of using support structures

Answer 8

increase material usage 
increase build time
increase energy usage 
increase post processing time
can be difficult to remove
can reduce the surface quality of the part because marks can be left behind

Question 9

What are some tactics for avoiding support structures?

Answer 9

Change build orientation 
Fill overhangs
Use self supporting structure
Segment the part
integrate supports

Question 10

What is generative design?

Answer 10

An iterative design process that generates multiple design outputs that meet predefined constraints
Allows a fast method for exploring design possibilities
Allows many hundreds if not thousands of possible solutions to be evaluated within a relatively short timeframe