Design for additive manufacturing (DFAM), also called design for 3D printing, is an increasingly discussed topic, particularly because people realize it can result in outcomes that more closely match a client’s expectations. Here are six compelling reasons why design matters for all additive manufacturing projects.

1. It Encourages More Collaborative Development

When 3D printing experts combine their knowledge, there’s a greater likelihood of continual progress. That’s likely the goal of a recently formed collaborative effort called the Design for AM Network. It aims to link academic researchers with 3D printing professionals, creating an overall broader audience that benefits.

So far, plans for the organization involve events like themed workshops and competitions. Additionally, people can get information about current research opportunities. When participants discuss what they know and which approaches they’ve tried, they play collective roles in helping future design efforts avoid pitfalls.

2. It Decreases 3D Printing Modeling Mistakes

Specialized software facilitates designing 3D printing models at the early stages of a project. When people take design considerations into account, they can steer clear of the blunders that could waste time and money.

For example, taking the printing material into account enables understanding whether a designer must consider specifics such as the need to strengthen protruding elements or support overhanging parts. Additionally, the technology used to print certain materials determines whether designers can print interlocking parts. Materials such as polyamide allow that, but resin does not.

3. It Facilitates New Opportunities

Many clients that rely on 3D printing realize it’s the best or sometimes only way to acquire a replacement part for an essential machine. Fortunately, the accelerated pace offered by additive manufacturing means customers can ask designers to quickly produce prototypes of several possibilities for a new product. 3D printing elevates design efficiency in technical applications.

However, even though the method broadens their options, it’s still necessary to consider design best practices at every phase. That includes assessing a client’s needs. In one case, a 3D printed part for an assembly needed the required strength to tolerate a long expected lifecycle for that component. That example shows why customer feedback and details about expected usage must be central parts of the design discussions.

4. It Drives Project Value

Focusing on design for 3D printing also allows people to identify practical ways to cause valuable outcomes for a client. For example, topology optimization can result in lighter 3D-printed parts. Then, a customer could see benefits like lower fuel consumption or faster acceleration in a vehicle. Designers can also tailor 3D printed materials to achieve objectives like increased wear resistance or better heat transfer effects.

Finding measurable expressions of value also allows designers to develop solutions that align with a manufacturer’s expected return on investment. For example, 3D printing gave GM a nine-week reduction in development time on brake cooling ducts. It also reduced the associated costs by more than 60%. Once a designer knows a client’s priorities, they can use their expertise to determine what strategies are most likely to meet them.

5. It Reduces the Need for Support Structures

There’s an ongoing effort to reduce the support structures used in a 3D-printed design. Succeeding in that goal reduces post-processing time and eliminates the damage that can occur while removing those no-longer-necessary parts. Relatedly, minimizing the use of support structures reduces the materials needed for a printing project.

Competent and thoughtful designers often explore options to cut the post-processing time. For example, some designs have support built into them, so it’s integral to the final piece rather than a removable part. That’s not yet a common approach, but it could become more popular as designers and clients seek to optimize processes.

6. It Allows Making Faster Tweaks

Implementing good design practices into additive manufacturing also enables the more efficient creation of updated models for a client’s review. Software made for 3D printing modeling allows users to save multiple versions and update them after receiving feedback.

Following well-established design principles makes it more likely that each new component will need extensive edits to satisfy the client. Moreover, when a part features forward-thinking design choices, 3D printing projects often significantly accelerate expected timelines.

In one example, a company needed to change the shape of a weaving bobbin line. Doing that with existing internal company practices would cost an estimated 1,200 hours and require an estimated $47,000 investment in labor and materials. However, when the business used its 3D printer to create adapters, it saved 90 days in lead time and 86% in costs. The brand also used a pioneering material that made the components nearly twice as strong.

Good Design Supports Future Successes

When professionals consider design for 3D printing, it doesn’t guarantee outstanding results for a project. However, as these examples show, additive manufacturing design considerations raise the probability of a company getting outcomes that meet or exceed expectations.

DFAM is crucial for helping people capitalize on additive manufacturing’s potential. Although the associated technologies allow creating more innovative parts faster, design is the foundation for those benefits and others.

Author Bio: Emily Newton is the Editor-in-Chief of Revolutionized. She is a journalist who covers the innovations impacting the construction and industrial sectors.

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