A d d i t i v e
t e c h n o l o g y
Design tips
for metal additive manufacturing
There are always tips and “tricks” that can make designing for additive manufacturing using metal materials easier and more productive. Here are a few.
1 Increase yield to same time and money Yield, in the context of additive manufacturing, is a function of feature parameters and process parameters. For example, with the Markforged systems, you can improve yield by considering the process itself, (which is fused filament fabrication (FFF)), and designing features that can be self-supporting. This means reducing the need for overhangs that require additional support. Another example is to consider the path the nozzle will take to place material. Notes Daniel Lazier, Strategic Application Engineer, at Markforged, “We see users shifting their mindset from one of the number of cuts, which is a very CNC focused mindset, to a more additive mindset where you’re only depositing material in the places where you need it, taking into consideration constraints like gravity and so on. There are efficient ways to place material, which can speed up the build process, improving yield. Also, consider using inlay lattice patterns rather than a solid build. Internal lattice 28
September 2021
patterns offer support using a minimal amount of material, reducing build time and cost.
2 Software for planning an additive layout Traditional CAD software programs did not always optimize for an efficient additive printing layout. Newer programs, such as generative design or topology optimization, help designers think about creating designs for additive manufacturing technologies. These programs will take design parameters on load, thermal, or aerodynamic requirements, for example, and then output oftentimes alien-looking features that optimize the solution to a problem. Then, slicer software aids in determining part settings and how to print the geometry. Noted Lazier, “Markforged offers a slicer program known as Eiger. Eiger includes the ability to customize a lattice structure that’s built up in the internal feature of the part. So, the outer shell is as designed, but the interior of the part may look like a honeycomb or a triangular truss structure.”
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