Recommended
More Related Content
What's hot
What's hot (20)
Similar to How to (re)Design your parts for Additive Manufacturing
Similar to How to (re)Design your parts for Additive Manufacturing (20)
Recently uploaded
Recently uploaded (20)
How to (re)Design your parts for Additive Manufacturing
- 1. How to (re)design your parts for Additive Manufacturing 26 Oct 2017 Cassidy Silbernagel
- 2. Review of Additive Manufacturing / 3D Printing Four ways to (re)design parts Case studies Overview
- 3. How does it work? 1 2 3 5 4 Image: dale3dps
- 4. Seven main categories: ISO/ASTM 52900:2015 1. Binder Jetting liquid bonding agent is selectively deposited to join powder materials 2. Directed Energy Deposition focused thermal energy is used to fuse materials by melting as they are being deposited 3. Material Extrusion material is selectively dispensed through a nozzle or orifice 4. Material Jetting droplets of build material are selectively deposited 5. Powder Bed Fusion thermal energy selectively fuses regions of a powder bed 6. Sheet Lamination sheets of material are bonded to form an object 7. Vat Photopolymerization liquid photopolymer in a vat is selectively cured by light- activated polymerization Image: 3D Hubs
- 5. Basic General Principles Supports / Overhangs Orientation Minimum feature size / Resolution Post Processing Learn More: https://www.3dhubs.com/knowledge-base https://www.linkedin.com/pulse/design-metal-am-beginners-guide-marc-saunders/ Image: 3D HubsImage: Cassidy SilbernagelImage: Marc Saunders
- 6. Four ways to (re)design parts Method 1 Send directly for AM Method 2 Modify for AM Method 3 Combine and redesign for AM Method 4 Rethink and redesign for AM
- 7. Method 1: Send directly for AM Advantages Easiest Less material wastage Direct single part replacement Potential faster lead times Allows easier manufacture of complex design Disadvantages Narrow scope of use Limited potential gains Image: Aron Igelström
- 8. Method 2: Modify for AM Advantages Improve performance Decrease weight Improve printability Direct single part replacement Less material wastage Disadvantages Requires same assembly methods and parts Image: Airbus Group
- 9. Disadvantages Requires more design time Requires testing and validation Method 3: Combine and redesign for AM Advantages Allows reduction of parts Reduce assembly Potentially less risk than a complete redesign of overall machine/assembly Image: GE Before After
- 10. Disadvantages Most amount of design effort Method 4: Rethink and redesign for AM Advantages Allows greatest performance increases Eliminate parts and assembly Reduce weight, cost, lead time Image: Optisys LLC
- 11. Method 3: Combine and redesign for AM Design for Additive Manufacturing Challenge 2016 Redesigned Electric Motor Casing Case Study 1
- 12. Creating an electric Honda CR 125 motorbike Original gasoline motor specs Torque: 28 Nm @ 11000 rpm Power: 30 kW @ 11500 rpm New electric motor specs Torque: 40 Nm @ 6000 rpm Power: 15 kW @ 6000 rpm
- 14. Thin wall integrated cooling channels
- 15. Minimized Supports – 45 degree angles
- 16. Motivations Show what Additive Manufacturing can do Multi-functional parts Light weight Enhanced cooling Eliminate parts It can do it today!
- 17. Method 4: Rethink and redesign for AM Design for Additive Manufacturing Challenge 2017 Redesigned Carburetor for an Internal Combustion Engine Case Study 2
- 18. Why a carburator? Original assembly count
- 19. How it works Choke plate Air inlet Fuel inlet FloatFloat bowl Venturi Fuel jets Throttle plate
- 22. Designed for Additive Manufacturing 45 degrees 45 degrees 45 degrees 45 degrees 45 degrees 45 degrees
- 23. Designed for Additive Manufacturing Thin walls Thin walls Thin walls Thin walls
- 24. Designed for Additive Manufacturing Minimal supports
- 25. Motivations Additive Manufacturing can Reduce the number of parts Contain moving parts Reduce weight Improve performance Make old designs new again!
Editor's Notes
- 99.9% of all 3D printers work on the same principle. Image: http://forum.3dprintingsystems.com/index.php?topic=249.0
- Binder Jetting Old Zcorp machines now 3D Systems, Voxeljet, ExOne machines. Originally called 3D Printing due to similarities to regular ink jet printing. Simply replace paper with layers of powder. This can be any powder including ceramics and metals. Directed Energy Deposition Known as either LENS or EBAM and either blows powder or feeds wire into a single heat source. Typically metal based but can be adapted to any material. Material Extrusion Anything that can be pushed through a nozzle fits into this category. Typically this is the one that most people know that produce plastic parts, but it can be adapted to print just about anything from food like chocolate, hydrogels with living cells within it, to metal and ceramic pastes which can sinter to produce the final desired material properties. Material Jetting These materials are typically nano-particles suspended as an ink. They are usually plastics or wax, but can now be metal with the recent XJet technology. Powder Bed Fusion Wide range of technologies from SLS, SLM, EBM, and even the new HP process which is a mix of technologies but primarily this one. Plastics, metals, ceramics can all be processed this way with different levels of success. Sheet Lamination Can be anything that starts as a sheet such as paper, metal, or even fabric or composite materials such as carbon fiber. Vat Photopolymerization This is the original additive manufacturing technology. The energy source that solidifies the liquid could be a laser or light source, and generally has the best surface finish of any process. It is generally limited to plastic type parts but has been shown to work to create ceramics with a post sintering process.
- All of these following principles differ greatly for each technology category. Some are not a concern, others are a major concern. Before you design for AM, you need to know which process you are designing for, and if possible, what machine it will be built upon. Each machine and even different materials differ on some of these aspects. https://www.linkedin.com/pulse/design-metal-am-beginners-guide-marc-saunders/ Supports / Overhangs Each technology deals with this differently. Generally, there is a critical angle (typically 45 degrees) that allows no support to be needed such as in the letter Y. Some need supports for all bridges of a certain length such as the middle of a capital H. Others need supports for overhangs such as at the ends of a capital T. How supports are designed or generated and removed needs to be thought of in the design process. Orientation Two factors come into play for orientation. First is material properties can differ depending on the direction they are built. This shows some test bars I printed to test how build orientation affects the electrical resistivity of a metal alloy. Strength can differ depending on build orientation so if you have a part that needs to have a certain strength in a certain direction, you will need to know how the orientation affects the strength of the part. The second is that printed features can come out looking differently depending on orientation. If you have a circle you want to print and have it come out circular, you will need to orient the part so that the circle is in the XY plane and not chopped up by the layers. Minimum feature size / Resolution This greatly depends on the process you use, and especially the machine you use. Just because two machines from different manufacturers use the same technology, they may not have the same feature specifications. There are also many factors that play into minimum features, and each are different. Here you can see some of the minimum sizes for a typical SLS process in Nylon. This is where you need to find out the machine and material specific specifications if you want to be designing features in the sub millimeter range. Post Processing There are many different ways post processing can affect how you design. If the process relies on supports, they will need to be removed manually, or potentially semi-automatically. If attached to a build plate, the parts will need to be removed. If there is excess powder or liquid trapped, it will need to be removed. If you want uniform or enhanced material properties, a heat treatment or post infusing of a secondary material may be needed. If you have critical surfaces that assemble, post machining will be required including custom part holding jigs or fixtures. All of these need to be taken into consideration when designing in order to gain the greatest benefits from AM.
- https://pinshape.com/items/7018-3d-printed-fully-assembled-3d-printable-wrench?utm_source=blog&utm_medium=post&utm_campaign=3dprintingmetal The first and easiest is to simply take an existing design and without modification create it using AM technology. This is advantageous when the single part is excessively complex making it difficult to produce using traditional methods or made from materials that are expensive where minimal waste is desirable.
- http://www.businesswire.com/news/home/20140204005189/en/EOS-Airbus-Group-Innovations-Team-Aerospace-Sustainability The second is to redesign the single part to either improve performance and/or to make the part better suited for AM.
- The third is to combine multiple parts to aid in part reduction, reduce assembly costs, and enhance performance. Before 3D printing, this fuel nozzle had 20 different pieces. Now, just one part, the nozzle is 25% lighter and five times more durable. http://www.techrepublic.com/article/how-ge-is-using-3d-printing-to-unleash-the-biggest-revolution-in-large-scale-manufacturing/ https://www.youtube.com/watch?v=rMzVSbNebCg&t=2m44s Before
- The fourth is to completely rethink the assembly and redesign according to basic first principles and design requirements. While this complete redesign can yield the greatest results, it takes the most time and effort to achieve. http://www.machinedesign.com/3d-printing/3d-printing-takes-parts-count-100-1-antenna The test project involved a complete redesign of a high-bandwidth, directional tracking antenna array for aircraft (known as a Ka-band 4×4 monopulse array). Reduce part count reduction from 100 discrete pieces to a one- piece device. • Cut weight by over 95%. • Reduce lead time 11 to two months. (eight months of development, three to six more of build time) • Reduce production costs by 20%. • Eliminate 75% of non-recurring costs.
- A few years ago, I had the opportunity to participate in converting a Motorbike from gasoline to electric. [Click] Once you remove all the parts that are no longer needed, you have quite a bit more room to fit an electric motor. Two things we didn’t want to remove were the [Click] Crankcase pictured here, and the liquid cooling system. [Click] This new motor was designed to fit in an Aluminium cylinder within the crankcase. The space between the Aluminium cylinder and the crankcase was attached to the existing cooling system and coolant flowed between the two. [Click] This new motor has much more torque than the original even though it has less power. But cooling was still an issue due to poor fluid control within the crankcase. [Click to next slide] Bike Image: http://www.vitalmx.com/forums/MotoRelated,20/CR125-2010-The-Real-Deal,905161 Motor Image: http://www.mxbonz.com/CR8001BK.jpg Casing Images: Myself Specs: http://www.motorbikes.be/en/Honda_CR_125_R_2003.aspx
- For this competition, I wanted to redesign the casing while keeping the shaft and other internal parts the same. [Click] Additive manufacturing allows the casing to not be cylindrical, which helps prevent internal components from rotating. I’ve also added a beveled channel along the length of the casing to allow for proper alignment and ease of assembly. [Click] The overall casing is comprised of two halves, which are identical. They sandwich the existing motor components together using through nuts and bolts, eliminating the need for threaded holes. This concept takes 8 different parts and merges them into one. [Click] O-ring grooves have been added for the bearings. Normally, bearings need a tight fit with high tolerances, higher than what metal additive manufacturing can achieve. This tightness prevents the outer part of the bearing from rotating. However, this tightness can also be achieved with O-rings. O-rings are normally used when a steel bearing is placed in an Aluminium case. As the case heats up, the Aluminium expands more than the steel bearing which causes looseness if an O-ring is not used. Thus O-rings can compensate for the as built tolerances of an additively manufactured case when is it made from stainless steel. [Click] The resulting design has all of the features that the electric motor needs within a single part. [Click to next slide]
- On the back of the casing are a number of holes. The three elongated wire pass-through holes take the wires out from the center of the motor. These holes make it easy to work with wires. Because if they are too tight or have sharp edges they would cut or nick the insulation off the wires which I’ve learned from experience can cause electrical problems later on. [Click] Near the top are the cooling inlet and outlet which can be hooked into the existing cooling system. [Click] These cooling channels are thin curved walls which are impossible to make with any other manufacturing process. In the middle of the cooling channel are angled cross pins. These increase the cooling ability of the liquid and improves motor performance. These pins could also be lattice structures. Despite the motor looking thick, the majority of this perceived volume is empty and is utilized by the cooling channels. Very little space is wasted in the design, as nearly every part has been optimized for one function or another. [Click] The front of the casing has been optimized and patterned after the output of the Inspire software provided for this competition in order to minimize weight while maintaining strength and stiffness. [Click to next slide]
- In order to aid in additive manufacturing, 45 degree angles have been incorporated in a number of areas in order to minimize support structures needed for overhanging parts. This can be seen on the interior of the casing, where the electric motor parts reside [Click] In the cutouts on the front of the casing, [Click] And even the angle of the interior cooling pins. [Click to next slide]
- So why did I do this? Well, I want to win, but [[Click]] what I really want to do is show what additive manufacturing can do. That we can take existing designs, and make them better. We can incorporate multiple features [[Click]] for alignment, cooling, wire management and assembly all in the same part [[Click]] without sacrificing weight. We can make these features better [[Click]] like incorporating pins or lattices in a cooling channel or [[Click]] by eliminating parts altogether. I believe that additive manufacturing is the future and I not only want to show the world what it can do,[[Click]] but that it can be accomplished today. [Click to next slide]
- So, after seeing last years winning entry seen here, I was inspired to include moving parts without any assembly. Typical carburetor (source: http://www.motorera.com/dictionary/pics/c/carb.gif) Exploded view carburetor (source: https://www.atkinsrotary.com/store/images/product/D/DCOE-01.jpg) I was also intrigued with this concept for a wave generator which can mix water into the air quite spectacularly. So I thought, what can I do with moving parts and can mix fluids, and I remembered the carburettor. Although they are an old way to mix air and fuel for internal combustion engines, they are still used today for motorcycles and some other vehicles. It has a lot of parts, but the concept is rather quite simple. I’ll explain using my redesign.
- First, air enters into it past the choke plate. It normally enters a smooth walled area but I’ve added swirling fins to help create a turbulent flow which will improve it’s performance of air and fuel mixing. Next it enters the venturi where the air speeds up due to the smaller cross section and causes a reduction in air pressure. I’ll talk more on this in a second. On the side, the fuel enters in through the fuel inlet and fills up the float bowl once its sealed with an O-ring. As the bowl fills up, it causes the float to float up. As it does, it blocks the fuel inlet. As fuel gets consumed, the fuel level drops and brings the float down with it, allowing more fuel in. This pattern repeats and maintains a even fuel level. Fuel gets pulled up to the fuel jets through the air pressure differential mentioned earlier which is a property of venturi’s. It’s a way to move fluids without any moving parts. These fuel jets can be customized and optimized for the performance of the motor. Then this air-fuel mixture flows past a throttle plate which is also rough and helps mixing further before it enters the combustion chamber.
- For the design of the float, I used the Inspire software extensively. I knew that I needed the float to fit within a certain volume, but didn’t what kind of shape to make. So I ran multiple iterations through the software which was really easy to use to come up with the final design of the float seen here.
- For the main body, I wanted to use a lattice structure to maintain stiffness while minimizing weight and was able to use some software developed by my University. It allows you to create lattice structures quickly and easily with a number of options to customize it according the design requirements. So I took my original CAD design and ran it through the software to create a fully latticed structure. I then hollowed out the original to maintain wall thicknesses in critical areas and merged the two together to create my final casing.
- In Additive manufacturing, 45 degree angles are utilized in order to minimize support structures. I’ve used them here, here, here, here and a few other places. It allows me to create a really complex part without having a complex support structure.
- I also utilized thin walls in areas that I wanted to minimize weight without needing to rely on a lattice structure.
- I’ve also created the required support structures to be in places that are easily accessible in order to aid in their removal. For example, from the bottom, the side, the back once you open up the part and remove the excess powder, and the top. Those highlighted regions are the only areas that need supports as the rest is self-supporting.
- So, why did I want to create this? Well, I wanted to show what Additive manufacturing can do. That I can reduce the number of parts, it can contain moving parts, I can reduce the weight, I can improve performance, and I can make old designs new again.