Each additive manufacturing technology has its own design principles, so that the advantages of the technology itself can be better utilized and the quality of component production can be improved. Jonathan Bissmeyer, senior quality engineer at Proto Labs, introduced the “Ten Design Dimensions†of Direct Metal 3D Printing (DMLS Technology). Xiaobian feels that only parts can be optimized for 3D printing after topology optimization and lightweighting. Advantages, then look at the technology cows together to see how to better avoid design loopholes! 1. First, the design of direct metal 3D printing should focus on two requirements: Reducing the number of parts Based on the metal 3D printing technology , the parts can be designed to be integrated, which can reduce the cost of assembly and maintenance, thereby saving costs. Of course, this also helps to reduce weight. The NextGen 3D printing car frame embodies the concept of integrated design. All steel components can be connected via 3D printing nodes, and the thickness and geometry of these nodes can be adjusted freely. Another strategy for weight loss is to carry out a hollow design. For manufacturing departments such as the aerospace industry, weight reduction is important because it saves fuel. 2. Precision detail Direct metal 3D printing equipment can achieve 0.006 inch forming accuracy. For some grid-like, sharp designs, this precision is too important. But of course not every part of the part has such a high precision. The rapid heating and cooling process during 3D printing imposes stress on the inside of the part, which causes some deformation and affects accuracy. The above five 2" high panels are designed to print at different thicknesses. The thinnest one is only 0.006 inches (0.15 mm) thick. The panel on the right is only a quarter of an inch high, then increase the height to the left. Of these components, the 1 mm thick part is the only one that does not warp. A general rule is that the vertical component height to wall thickness ratio should be maintained at around 40:1. When designing, the unsupported vertical structure can be reduced, and the portion of the package reinforcement is provided at the edge portion. 3. Surface accuracy The surface finish of DMLS components is often seen as a challenge. Surface roughness can vary depending on the material, construction parameters, and component path. By adjusting the parameters, the surface roughness can be reduced to some extent, but the material parameters may be sacrificed accordingly. Subsequent auxiliary operations (such as machining, hand polishing) can reduce surface roughness, but some special surfaces may be difficult to handle directly. In addition, the cost of these post-processing is a big problem. Comparison of typical Ra values ​​for different materials and print paths (devices are two Concept Laer DMLS 3D printers ) 4. External support In DMLS components, there are two reasons for setting the support: fixing the components in place and eliminating internal stresses during the printing process. When the part has a thick cross section, it is necessary to increase the support to prevent warpage. Whether it is to increase support or to support, it takes time and cost. Therefore, considering this aspect in design, it is critical to minimize support. 5. Internal feature On the basis of additive manufacturing, you can create internal features in the files of individual parts, but this must be done with caution. Consider the channel size and shape, the overhang distance, the internal support angle, and the size of the joint. It is conceivable to replace the internal voids with a self-supporting lattice structure, which not only greatly reduces the weight of the components, but also reduces the internal stress during printing. 6. Internal (self) support Such as self-supporting angle design. The lower the angle, the smaller the support capacity. The actual angular value is adjusted according to the material and the printing path. The 45° angle generally supports the surface better and maintains a consistent surface roughness. 7. Overhanging structure Draping is a key component to consider in design. An overhang is a sudden change in geometry compared to a gradually self-supporting angle. Unlike other 3D printing technologies, DMLS has limited ability to retain unsupported overhang structures. When the unsupported overhang reaches 0.020 inches (0.5 mm), it is easy to fail the build. 8. Internal channel More and more components will have conformal cooling channels and mold gaps. The conformal cooling channel extends component life. In the setting of the internal channel, you must first understand the size limit. Channels larger than 8 mm in diameter may be deformed downwards, in which case the shape of the diamond and water droplets may be better than the conventional circular channel. 9. Connection surface The connecting surface is a flat portion that functions as a connection between two sides or multiple sides. In the DMLS technology, the unsupported distance span is more than 2 mm, which is prone to problems. 10. Internal stress Rapid heating and cooling create internal stresses. Transitional arches between vertical faces/columns can reduce or eliminate internal stresses. Large solid parts are prone to warping. In addition to the incorrect print start position, low adhesion may also be one of the reasons. Adding support and setting a larger cross section helps to eliminate internal stresses. 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Generally speaking, the surface that is inclined downward at an angle is the roughest, while the surface of the vertical sidewall is finer and smoother. Therefore, it is best to determine the key surfaces and features before 3D printing. 
