1. Disrupting Design Processes
through
ADDITIVE MANUFACTURING

2. Disruption:
Constructive disruption is the deliberate unsettling of the
way you’re most comfortable thinking or working.
It allows / forces you to create your own framework for
rendering palpable, the workings of your mind, as it tries
to create order and meaning.
Disruption for the sake ?
NO

3. 2D Manual Sketch
finalization
1:1 Sketch
Templates
- - - - - - - - -
- - - - - - - - - -
Clay Model
Digitize
Clay milling
3D model
Wooden mockup
Digitize
Temp Toolings
Components
layout check
Testing
Final Toolings
- - - - - - - - -
- - - - - - - - - -
Endurance testing
Market Release
3D Sketching
(Morphology based
topological
optimization)
R P/ Additive Model
Additive
manufacturing or
Final Tooling
Release to market
convergence

4. Technologies that caused DISRUPTION
Morphology based Topological Optimization
3D Sketching
Blue light scanning
Virtual Protoyping
Additive manufacturing

5. Additive
Manufacturing
Virtual
prototyping3 D
Sketching
Blue light
scanning
digitizing
Morphology
based
topological
optimization
PLM based
concurrent
design
Artificial
intelligence
Information
Technology
(IOT etc.)
Additive Manufacturing is the biggest
star

6. Rapid Prototyping :
FANCY ?
NO, not any more.
They are a necessity, if you want to remain competitive.
At clay model stage,
complex small parts
3D sketching
After Sketch, Clay,
Scan, Surface
After Sketch, Clay,
Scan, Surface , Clay
mill, Scan
After sketch, Model,
3D Solid model
(engineered)
Mockup
Functional
Test worthy
Additive
Manufacturing Proto/

7. Cost in terms of cash outflow
Reduction in Design throughput time
Design for Additive manufacturing
Multiple part assy as one
Early Aesthetic evaluation
Easy to paint / check with multiple
parts
Ergonomic s
Tactile finish
Textures
RP Facts

8. Rapid Manufacturing
Parts : limited addition/
Customized
Tools : Injection Moulds.
Assembly Jigs
Machining Fixtures
Inserts
Studio
Basic frame / core for clay

9. Additive Manufacturing:
Processes
SLA
SLS
FDM
3D Printing
SLM
Metal Printing
Sand Printing
Understand the process , its strength.
Select the process based on application. ( help achieve the Goal)

10. Challenges:
Mechanical properties are not isotropic
Still large lead time
Higher Cost ( for large volume)
But then again
It’s important to remember that disruption is a positive force.
Disruptions are not use of breakthrough technologies that make good
processes better; rather they are innovative application of new technologies
that affects the overall cycle in a way , that never was.