Product Development & DfAM in the Dawn of Digital Transformation
Empire Group provides a glimpse into the future of product development and how an understanding of DfAM is critical to the success of PD professionals and manufacturers alike. You’ll learn some of the basic fundamentals of DfAM and see real-world design examples and optimizations from Empire Group’s Design & Engineering team.
Website: www.empiregroupusa.com
Phone: 508-222-3003
email: info@empirepd.com
Lecture # 03 Design for Additive ManufacturingSolomon Tekeste
Design for Additive Manufacturing (DfAM)
DfAM - A generic term used to describe rules and parameters for a part design to be produced with an AM process
DfAM - is the practice of designing products to reduce or minimize manufacturing and assembly difficulties and costs,
DfAM aims
To take advantages of the unique AM technologies capabilities to design and optimize a product/component,
To utilize the characteristics of AM methods to improve the product/component functions according to the capability of the selected AM process.
In doing so, the designers should tailor their designs to maximize the advantages of AM methods, such as complex geometries and lightweight
Design Aspect and Design Consideration in AM
Design aspect
Any particular feature which can be quantified at the design phase.
Includes;
Geometric features of the part’s shape (overhangs, bores, channels, etc.)
Part’s programming parameters (layer thickness, orientation, etc.).
Design consideration
The result on the manufactured part
Specific properties of the process and quantified with certain key performance indicators.
These includes; surface roughness, accuracy, build time, etc.
Design Aspect and Design Consideration in AM
With conventional manufacturing processes, these aspects are mostly a concern for the production engineer rather than for the designer;
But, the significance of these aspects is high for the outcome in AM technologies.
Lecture # 03 Design for Additive ManufacturingSolomon Tekeste
Design for Additive Manufacturing (DfAM)
DfAM - A generic term used to describe rules and parameters for a part design to be produced with an AM process
DfAM - is the practice of designing products to reduce or minimize manufacturing and assembly difficulties and costs,
DfAM aims
To take advantages of the unique AM technologies capabilities to design and optimize a product/component,
To utilize the characteristics of AM methods to improve the product/component functions according to the capability of the selected AM process.
In doing so, the designers should tailor their designs to maximize the advantages of AM methods, such as complex geometries and lightweight
Design Aspect and Design Consideration in AM
Design aspect
Any particular feature which can be quantified at the design phase.
Includes;
Geometric features of the part’s shape (overhangs, bores, channels, etc.)
Part’s programming parameters (layer thickness, orientation, etc.).
Design consideration
The result on the manufactured part
Specific properties of the process and quantified with certain key performance indicators.
These includes; surface roughness, accuracy, build time, etc.
Design Aspect and Design Consideration in AM
With conventional manufacturing processes, these aspects are mostly a concern for the production engineer rather than for the designer;
But, the significance of these aspects is high for the outcome in AM technologies.
this short ppt gives you a rough idea about the additive manufacturing process of stereolithography. This process is apart of 3d printing technologies around us. Also included is link to a video that will help you further.
BAHIR DAR UNIVERSITYBAHIR DAR INSTITUTE OF TECHNOLOGY (BiT)FACULTY OF MECHANICAL AND INDUSTRIAL ENGINEERING Rapid Prototyping & Reverse Engineering [MEng6123]
Post processing of AM parts
Post processing of AM parts
Post processing of AM parts
Post processing of AM parts
Post processing of AM parts
Post processing of AM parts
Post processing of AM parts
Post processing of AM parts
Post processing of AM parts
Post processing of AM parts Preparation for use as a Pattern Often
Guidelines for process selection
Guidelines for process selection Approaches to Selection
Guidelines for process selection Selection Example
Guidelines for process selection - Selection Example
In this example, it is decided to allow customization of certain features.
Only standard 12 mm diameter x 100 mm length bolts will be used for the inner bore, therefore, these dimensions will be constrained.
Customers will be allowed to customize all other features of the caster wheel
within allowable ranges for this model wheel, as displayed in the table below.
Guidelines for process selection - Selection Example
Guidelines for process selection Selection Example
In this example, we examine two weighting scenarios (relative importance ratings).
Scenario 2
All selection attributes were equally weighted.
Guidelines for process selection Selection Example
Selective Laser Sintering is one of the most used processes of Rapid Prototyping. It is a powder based process where powder of different metals/materials get sintered by LASER.
FDM Process introduction (A part of Additive Manufacturing Technique OR Commonly Known as 3D Printing). 3D printing is an evolved manufacturing technique; it is comparatively better than conventional substractive manufacturing. There is minimum wastage of material because material is added only at those locations where it is required. To make 3D model you need a 3D printer and feeding material and obviously power source. Any thermoplastic material whose melting temperature lies in the range of 150-240 deg. C can be used in FDM based 3D printing.
additive manufacturing introduction presentation
only for educational purposes
should not be published without permission
Biblography-Wikipedia,Slideshare,Google Search,ReseachGATE
Definition, need, raw materials, types of processes
Photo polymerization
Binder jetting, material extrusion
Powder bed fusion
Sheet lamination, direct energy deposition
Limitations, strengths
Programming methods.
Stereolithography (SLA) is the oldest 3D Printing technology used to manufactureaesthetically beautiful and proof of concept prototypes with smooth surface finish. We use photopolymer resins to manufacture the parts in SLA technology. The parts find applications in Automotive interiors, Industrial goods, Medical Devices industries etc.
DFMPro® is a powerful design for manufacturability solution that assists design engineers to pre-empt and address downstream manufacturing, assembly, quality and serviceability issues at an early design stage. To know more visit http://dfmpro.geometricglobal.com/
A case study on concurrent engineering in the development of automotive components using DFMA/DFX approach.
DFMA- DESIGN FOR MANUFACTURING AND ASSEMBLY.
“Design for manufacture” means the design for ease of manufacture for the collection of parts that will form the product after assembly.
“Design for assembly” means the design of the product for ease of assembly.
this short ppt gives you a rough idea about the additive manufacturing process of stereolithography. This process is apart of 3d printing technologies around us. Also included is link to a video that will help you further.
BAHIR DAR UNIVERSITYBAHIR DAR INSTITUTE OF TECHNOLOGY (BiT)FACULTY OF MECHANICAL AND INDUSTRIAL ENGINEERING Rapid Prototyping & Reverse Engineering [MEng6123]
Post processing of AM parts
Post processing of AM parts
Post processing of AM parts
Post processing of AM parts
Post processing of AM parts
Post processing of AM parts
Post processing of AM parts
Post processing of AM parts
Post processing of AM parts
Post processing of AM parts Preparation for use as a Pattern Often
Guidelines for process selection
Guidelines for process selection Approaches to Selection
Guidelines for process selection Selection Example
Guidelines for process selection - Selection Example
In this example, it is decided to allow customization of certain features.
Only standard 12 mm diameter x 100 mm length bolts will be used for the inner bore, therefore, these dimensions will be constrained.
Customers will be allowed to customize all other features of the caster wheel
within allowable ranges for this model wheel, as displayed in the table below.
Guidelines for process selection - Selection Example
Guidelines for process selection Selection Example
In this example, we examine two weighting scenarios (relative importance ratings).
Scenario 2
All selection attributes were equally weighted.
Guidelines for process selection Selection Example
Selective Laser Sintering is one of the most used processes of Rapid Prototyping. It is a powder based process where powder of different metals/materials get sintered by LASER.
FDM Process introduction (A part of Additive Manufacturing Technique OR Commonly Known as 3D Printing). 3D printing is an evolved manufacturing technique; it is comparatively better than conventional substractive manufacturing. There is minimum wastage of material because material is added only at those locations where it is required. To make 3D model you need a 3D printer and feeding material and obviously power source. Any thermoplastic material whose melting temperature lies in the range of 150-240 deg. C can be used in FDM based 3D printing.
additive manufacturing introduction presentation
only for educational purposes
should not be published without permission
Biblography-Wikipedia,Slideshare,Google Search,ReseachGATE
Definition, need, raw materials, types of processes
Photo polymerization
Binder jetting, material extrusion
Powder bed fusion
Sheet lamination, direct energy deposition
Limitations, strengths
Programming methods.
Stereolithography (SLA) is the oldest 3D Printing technology used to manufactureaesthetically beautiful and proof of concept prototypes with smooth surface finish. We use photopolymer resins to manufacture the parts in SLA technology. The parts find applications in Automotive interiors, Industrial goods, Medical Devices industries etc.
DFMPro® is a powerful design for manufacturability solution that assists design engineers to pre-empt and address downstream manufacturing, assembly, quality and serviceability issues at an early design stage. To know more visit http://dfmpro.geometricglobal.com/
A case study on concurrent engineering in the development of automotive components using DFMA/DFX approach.
DFMA- DESIGN FOR MANUFACTURING AND ASSEMBLY.
“Design for manufacture” means the design for ease of manufacture for the collection of parts that will form the product after assembly.
“Design for assembly” means the design of the product for ease of assembly.
Is Additive Metal Manufacturing the Next Technological Wonder Drug? An article in Canadian Metalworking Magazine reviewing AMM's success with their two (2) EOS Model M290 e-Manufacturing DMLS Systems.
Fast and seamless 3D printing begins with solid 3D designs. And this is where SOLIDWORKS comes in, as it encompasses a complete suite of design solutions that make it quick and easy to prepare designs for print.
Engineering Technique is an India’s leading 3D Engineering Company provides SOLIDWORKS 3D CAD Solutions to 3D Printing Services at affordable prices. Contact NOW for more information. www.enggtechnique.com
Startup Advisor Lunch & Learn: Impact WashingtonJessy Arter
These are the slides from the November 2022 Lunch & Learn with presenter Nick Wilkes from Impact Washington.
Learn what you need to know from the beginning of your business to avoid the pitfalls that increase manufacturing costs.
Subscribe to our YouTube channel to be notified when the presentation recording becomes available: https://www.youtube.com/@sp3nw120
Squeeze Time and Money out of Production Using Design for ManufacturabilitySOLIDWORKS
Product design does not occur in a vacuum and has a significant impact on manufacturing. In fact, 3D design carries even greater potential for streamlining production processes, especially when you take advantage of Design for Manufacturability tools and applications. With these technologies, you can avoid the manufacturing delays, cost overruns, and shop-floor retrofits that work against your company’s success and competitive position.
Additive Manufacturing: 3D Printing--Past, Present, and Future360mnbsu
This presentation explored the foundation of ‘the next industrial revolution’ - how additive manufacturing systems such as 3D printers and 3D production systems are changing the future of product development and manufacturing. Mr. Fischer presented examples of how design engineers use 3D production systems for concept modeling and prototyping, but also how manufacturing engineers are now employing these technologies for various applications such as jigs, fixtures, check gauges, and even as a bridge-to-tooling and low-volume end-use parts.
From the 2013 Taking Shape Summit: Additive Manufacturing: 3D Printing--Beyond Rapid Prototyping.
Digital Design Solutions is a premier provider of Siemens PLM NX CAD/CAM/CAE software solutions to various industries. These are located in Delhi, NCR, Gurgaon (Gurugram) and all over India. DDS current range of products includes NX 12, NX CAD, NX CAM, NX Nastran, Simcenter, LMS, Dynaform, QForm, Moldex, Rapidauthor.
Kenneth Tardif, engineering supervisor (and part time CAD administrator) from Hardigg Industries spoke about their early experiences using Solid Edge with Synchronous Technology
Additive manufacturing 3D Printing technologySTAY CURIOUS
Additive manufacturing 3D Printing
3D printing is the process of building an object one thin layer at a time. It is fundamentally additive rather than subtractive in nature. To many, 3D printing is the singular production of often-ornate objects on a desktop printer.
Similar to Product Development & Design for Additive Manufacturing (DfAM) (20)
Explore the innovative world of trenchless pipe repair with our comprehensive guide, "The Benefits and Techniques of Trenchless Pipe Repair." This document delves into the modern methods of repairing underground pipes without the need for extensive excavation, highlighting the numerous advantages and the latest techniques used in the industry.
Learn about the cost savings, reduced environmental impact, and minimal disruption associated with trenchless technology. Discover detailed explanations of popular techniques such as pipe bursting, cured-in-place pipe (CIPP) lining, and directional drilling. Understand how these methods can be applied to various types of infrastructure, from residential plumbing to large-scale municipal systems.
Ideal for homeowners, contractors, engineers, and anyone interested in modern plumbing solutions, this guide provides valuable insights into why trenchless pipe repair is becoming the preferred choice for pipe rehabilitation. Stay informed about the latest advancements and best practices in the field.
Immunizing Image Classifiers Against Localized Adversary Attacksgerogepatton
This paper addresses the vulnerability of deep learning models, particularly convolutional neural networks
(CNN)s, to adversarial attacks and presents a proactive training technique designed to counter them. We
introduce a novel volumization algorithm, which transforms 2D images into 3D volumetric representations.
When combined with 3D convolution and deep curriculum learning optimization (CLO), itsignificantly improves
the immunity of models against localized universal attacks by up to 40%. We evaluate our proposed approach
using contemporary CNN architectures and the modified Canadian Institute for Advanced Research (CIFAR-10
and CIFAR-100) and ImageNet Large Scale Visual Recognition Challenge (ILSVRC12) datasets, showcasing
accuracy improvements over previous techniques. The results indicate that the combination of the volumetric
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adversary training.
Hybrid optimization of pumped hydro system and solar- Engr. Abdul-Azeez.pdffxintegritypublishin
Advancements in technology unveil a myriad of electrical and electronic breakthroughs geared towards efficiently harnessing limited resources to meet human energy demands. The optimization of hybrid solar PV panels and pumped hydro energy supply systems plays a pivotal role in utilizing natural resources effectively. This initiative not only benefits humanity but also fosters environmental sustainability. The study investigated the design optimization of these hybrid systems, focusing on understanding solar radiation patterns, identifying geographical influences on solar radiation, formulating a mathematical model for system optimization, and determining the optimal configuration of PV panels and pumped hydro storage. Through a comparative analysis approach and eight weeks of data collection, the study addressed key research questions related to solar radiation patterns and optimal system design. The findings highlighted regions with heightened solar radiation levels, showcasing substantial potential for power generation and emphasizing the system's efficiency. Optimizing system design significantly boosted power generation, promoted renewable energy utilization, and enhanced energy storage capacity. The study underscored the benefits of optimizing hybrid solar PV panels and pumped hydro energy supply systems for sustainable energy usage. Optimizing the design of solar PV panels and pumped hydro energy supply systems as examined across diverse climatic conditions in a developing country, not only enhances power generation but also improves the integration of renewable energy sources and boosts energy storage capacities, particularly beneficial for less economically prosperous regions. Additionally, the study provides valuable insights for advancing energy research in economically viable areas. Recommendations included conducting site-specific assessments, utilizing advanced modeling tools, implementing regular maintenance protocols, and enhancing communication among system components.
CFD Simulation of By-pass Flow in a HRSG module by R&R Consult.pptxR&R Consult
CFD analysis is incredibly effective at solving mysteries and improving the performance of complex systems!
Here's a great example: At a large natural gas-fired power plant, where they use waste heat to generate steam and energy, they were puzzled that their boiler wasn't producing as much steam as expected.
R&R and Tetra Engineering Group Inc. were asked to solve the issue with reduced steam production.
An inspection had shown that a significant amount of hot flue gas was bypassing the boiler tubes, where the heat was supposed to be transferred.
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Based on our results, Tetra Engineering installed covering plates to reduce the bypass flow. This improved the boiler's performance and increased electricity production.
It is always satisfying when we can help solve complex challenges like this. Do your systems also need a check-up or optimization? Give us a call!
Work done in cooperation with James Malloy and David Moelling from Tetra Engineering.
More examples of our work https://www.r-r-consult.dk/en/cases-en/
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2. Empire Group is a full-service product development company that enables
product developers, designers, engineers, and entrepreneurs to move with
speed, flexibility, and confidence through ALL stages of product
development, from virtually any starting point.
ABOUT EMPIRE GROUP
CREATE. ITERATE. ACCELERATE.
TMt
3. INTRODUCTION
“An industry once considered a gimmick is proving itself
to be a formidable giant. Make no mistake: 3-D printing
will be a force that upends nearly every industry over the
coming decade.” – Forbes Technology Council
“We are going to live in a world where anyone can
create and customize, and iterate with blinding speed.”
– Financial Expert @ Forbes
“It’s going to usher in a new era of localized, distributed
manufacturing that is actually based on digital
fabrication.” – Avi Reichental (CEO of 3D Systems)
THE IMPACTS OF ADDITIVE MANUFACTURING
4. EVOLUTION OF ADDITIVE
The 1980s: Birth of the 3 main 3D Printing Techniques
The 1990s: The Rise of 3D Printers, Manufacturers & CAD tools
The 2000s: 3D Printing “Goes Viral”
2010s - Present: Rapid Adoption of Additive Manufacturing
The Future: Industry 4.0
RAPID EXPANSION IN TECHNOLOGY
7 Categories of Additive Manufacturing
Processes and 20+ 3D Printing Technologies
5. WHAT IS
INDUSTRY 4.0?
It is a “buzzword” describing a digital
transformation in manufacturing.
The inevitable culmination of:
Artificial Intelligence
Robotics
IoT Technology
Data
Additive Manufacturing
6. WHAT DOES THIS
MEAN FOR PRODUCT
DEVELOPMENT?
Innovation in process calls for innovation in design
Breakthroughs in manufacturing ≠ breakthroughs in design
Largest impact on design and engineering
Steep learning curve
Test processes and materials, iterate designs, and prepare
now for the transformation
Early adoption = competitive advantage
“A MAN WILL BE IMPRISONED IN A ROOM WITH A DOOR
THAT'S UNLOCKED AND OPENS INWARDS; AS LONG AS
IT DOES NOT OCCUR TO HIM TO PULL RATHER THAN
PUSH.” - LUDWIG WITTGENSTEIN
MJF Manufactured Parts/Product
8. REWRITTING THE RULE BOOK FOR
MODERN DESIGN AND ENGINEERING
THINK DfAM
Design for Manufacturing (DFM): Optimizing the part design
for manufacturing feasibility and bringing down costs
Design for Assembly (DFA): Design to reduce cost by
making the assembly process easy
Design for Additive Manufacturing (DfAM): Design for
part consolidation. Process specific. Purpose specific.
MJF Manufactured Promo Item
Source: “7 PRINCIPLES FOR DESIGN FOR ADDITIVE MANUFACTURING (DFAM)”, Simon Indrele, Fischer Unitech 2018
9. DfAM PROS & CONS
Design freedom and flexibility
Part consolidation
Stronger parts, lighter weight, complexity
Accelerated development cycle
Immediate feedback on design
PROS
Steep learning curve
Design is process specific
Machines are costly
New & evolving technologies
Material limitations
CONS
HP printheads manufacturing line: Drill extraction shoe
10. APPLICATION
When significant cost savings can be realized
When the materials available meet production requirement
Low volume, high complexity, highly customized products
Low-mid volume like-products, materials meet needs
WHEN TO USE AM FOR PRODUCTION
Carbon 3D Manufactured Shoe
MJF Manufactured Parts/Product
11. Vat Polymerization (SLA)
Powder Bed Fusion (SLS, MJF*)
Material Extrusion (FDM)
Digital Light Synthesis (DLS*)
WELL-KNOWN PROCESSES
*HPs MJF & Carbon’s DLP are the only plastics technologies
currently used for true production at this time.
12. DESIGN PRINCIPLES
General rules of thumb:
Parts should be redesigned for AM and not simply
reproduced using an AM process.
Designers & Engineers adopting DfAM must extend
their line of thinking to the entire production system.
DfAM is best implemented when there are clear lines
of communication from concept to production.
“IN AM, COMPLEXITY IS FREE. SO STEP BACK AWAY FROM
THE CONSTRAINTS OF OLD. JUST LET YOUR MIND SOAR,
DESIGN WHAT YOU WANT AND LET THE SOFTWARE DO THE
REST.” – AVI REICHENTAL (CEO OF 3D SYSTEMS)
13. DESIGN CONSIDERATIONS
What are your requirements? What is most important?
Nice-to-haves vs. must-haves? Tradeoffs in cost, quality, and time.
RESOURCE REDUCTION QUALITY ENHANCEMENT
Weight & Cost Print Time Touch Time Strength Aesthetic Functionality
Think Additively
Design for Orientation
Topology Optimization
Segment Parts
Add Hardware
Minimize Complication
Critical Surface Treatment
End-use/production
Source: “7 PRINCIPLES FOR DESIGN FOR ADDITIVE MANUFACTURING (DFAM)”, Simon Indrele, Fischer Unitech 2018 - Adapted from original by Empire Group 2019
14. DESIGN CONSIDERATIONS (CONT.)
Material properties (chemical, mechanical)? What is most important?
Material choice will narrow your process options.
MATERIAL EXAMPLE PROCESS CATEGORY
VAT
Photopolym
erization
Material
Jetting
Binder Jetting
Powder Bed
Fusion
Material
Extrusion
Directed
Energy
Deposition
Sheet
Lamination
Thermoset
Polymers
Epoxies &
Acrylates
X X
Thermoplast
ic Polymers
Polyamide, ABS,
PPSF
X X X X X
Metals
Steel, Titanium
Alloys, Cobalt,
Chromium
X X X X
Industrial
Ceramics
Alumina,
Zirconia, Silicone
Nitride
X X X X
Structural
Ceramics
Cement,
Foundry Sand
X X X
15. DESIGN CONSIDERATIONS (CONT.)
Post-processing – Build-lines, support-
removal, tolerances with paint/coatings,
texture, dimensional requirements after
finishing
“Tool Safe” Design – Start robust so there is
room to adjust tolerance, clearance, wall
thickness etc.
Topology Optimization - Removal of
unnecessary material leaving load paths.
Mathematically efficient design in weight and
strength.
16. DESIGN CONSIDERATIONS (CONT.)
Part Orientation - Support reduction,
critical surface specification
Trapped Powder or Resin – Create
escape holes for liquid or powder, or
honeycomb solid parts to decrease
weight
Resolution – Higher resolution files =
longer print time vs. Lower-resolution
files = faster production
17. KEY TAKEAWAYS
A digital transformation in manufacturing is in motion,
stay at the forefront of technology
Designers & Engineers need DfAM knowledge
Design has yet to catch up to technology
Best implemented when there are clear lines of
communication from concept to production
DfAM is not “one-size-fits-all”
Design without traditional constraints
Current production is limited to low-mid volume, end-use.
But not for long.
19. 360° PRODUCT
DEVELOPMENT
SUPPORT
With Empire Group, Customers Have Access to
and gain a trusted partner that provides design, development,
and manufacturing solutions that push the boundaries of
technological advancement.
20. DESIGN PROTOTYPE MANUFACTURE MARKET
Industrial Design
Engineering
Graphic Design
3D Printing
Model Making
CNC Machining
RTV Molds & Casting
Metal Fabrication
Thermoforming
Custom Finishing
Samples & Displays
Short Run Production
SERVICES FOR EVERY STAGE
OF PRODUCT DEVELOPMENT
21. OUR FACILITIES
20,000 sq. ft. Building
State-of-the-art 3D Printing Lab
CNC Machine Shop
RTV Mold & Casting Department
Model Shop
Design & Engineering Studio
Conveniently located in Attleboro, MA
and neighboring RI, CT and NY.