Design for Additive Manufacturing Principles — Lesson 1

This lesson covers the principles, techniques, and steps of Design for Additive Manufacturing (DfAM). It delves into the paradigm shift in manufacturing where assembly is integrated into the fabrication process. The lesson discusses the fundamentals of DfAM, its application fields, techniques, and steps. It also explores case studies with examples, design optimization, material selection, and considerations in DfAM. The lesson further explains the application of DfAM in lightweight structures, part consolidation, functional customization, personalization, and aesthetics. It also introduces DfAM simulation software and the process of design optimization.

Video Highlights

00:41 - Explanation of the paradigm shift in additive manufacturing where assembly is integrated into the fabrication process
08:17 - Discussion on the importance of design for orientation and its impact on the final part's microstructure
16:00 - Introduction to opportunistic and restrictive DfAM, and their respective roles in the design process
22:20 - Case study of DfAM involving an existing part redesign for reduced volume and improved portability
30:39 - Explanation of considerations for DfAM including the need for anchor supports, build supports, and the rougher surface finish of AM parts

Key Takeaways

- DfAM integrates assembly into the fabrication process, leading to a major shift in manufacturing principles.
- DfAM principles include thinking additively, designing for orientation, contour design, segmenting and bonding parts, adding hardware, minimizing complications, and critical surface treatments.
- DfAM techniques include multi-material design, phase optimization, integrated structure, and lattice alternative.
- DfAM steps involve selecting a build direction, adding allowance material, changing geometry, making the design self-supporting, and integrating non-moving parts.
- DfAM is applied in various fields including lightweight structures, part consolidation, functional customization, personalization, and aesthetics.
- DfAM simulation software like INSPIRE, ANSYS Suit, 3D-Matic, Hyperworks, and SimSolid are used for design optimization.