Product Development for Additive Manufacturing

Additive manufacturing unlocks exciting possibilities in product design, providing solutions that are often impossible to achieve using traditional manufacturing methods. For components that are complex, large, heavy, or costly to produce conventionally, additive manufacturing can be an excellent alternative. It is also particularly well-suited for prototype creation during the product development phase, as the technology allows for quick iterations.

But before you begin optimising component design and production documentation, it's important to ask the question: Is additive manufacturing the right manufacturing method for this component?

To determine that, you need to identify the requirements for each component and conduct a thorough analysis that includes both technical and economic aspects.

From Analysis to Optimisation

The Application Center for Additive Manufacturing supports your organisation in determining whether additive manufacturing is the right solution for your product, allowing you to make an informed decision. We offer expertise in product design, production planning, process development, and material optimisation. To meet your company's needs, we can form a team with the right skills for both analysis and hands-on implementation. Additionally, we provide access to the tools and software you need.

What is the difference between conventional product design and design for AM?

Design for additive manufacturing (AM) provides the flexibility to create complex geometries – such as internal channels, lattice structures, and integrated features – that would be either cost-prohibitive or impossible with traditional methods. While conventional design often requires components to be split into multiple parts for machining and assembly, AM allows for the consolidation of functions into a single component, reducing the need for assembly and fasteners. This integration facilitates both weight and material optimisation without compromising strength.

However, AM design comes with unique requirements, such as support structures, particularly for overhangs and angled surfaces, to ensure the component remains stable during manufacturing. These support structures need careful planning and often must be removed after production, which can affect production time and surface finish. Additionally, consideration must be given to the risk of deformation, especially in large components or when using certain materials, as temperature variations can lead to shrinkage or warping.

Post-processing is also a key part of the AM process, where techniques such as grinding, heat treatment, or surface finishing may be required to meet desired tolerances and functional properties.

By strategically addressing these AM-specific factors in the design phase, it's possible to ensure optimal performance and production quality while fully exploiting the unique advantages of AM technology.

What is optimisation for AM?

Optimisation for AM means improving an existing design to make it more efficient for manufacturing with AM, without necessarily completely changing it. This can involve adapting a conventional design, such as one made for casting, for AM, or refining an existing AM design to enhance quality throughout production. This may include analysing and optimising support structures during the build phase, the orientation of the component in the build chamber, potential internal lightweight structures, and their impact on the component's properties and functionality.