Generative Design for Metal 3D Printing

Generative Design for Metal 3D Printing
Amit Aware

Founded “AMISON Engineering” to cater industry need for design and manufacturing services for conventional and Additive manufacturing technologies.

Adopting a AM technology is always a challenge. It is always helpful to work together with the industry and taking AM expert into consideration. This project where Amison Engineering re-designed a bracket using Generative Design methodology and applying DfAM (Design for AM) principles is a great example for us and client to understand AM advantage.

Problem

Client was using this bracket which gets fit in their final structure where quantity was 250 numbers in single unit. It was always the lead time of this units was delaying project. Short batch with quicker delivery to expedite production and making unit lighter was the main objective for the client to adopt AM technology.

Solution

There’s a common misconception in the industry, wherein, people often think that the only applications of additive manufacturing (AM) are rapid prototyping and minimal quantity manufacturing for aerospace applications. Contrary to this, AM can also be used for batch production of components that are required in lesser quantities, as compared to high-volume production.

Economics of using metal 3D-printing over traditional manufacturing is mainly driven by the Output/Quantity vs Unit Cost graph. In traditional manufacturing, the unit cost rapidly decreases as we build more quantities. Therefore, it only makes economic sense to use 3D printing for parts that fall behind this breakeven point; which is why it is used so frequently for rapid prototyping and limited sized batch production. AMISON Engineering executed an innovative project, in which the cost of manufacturing 500 metal components was significantly reduced by over 18%, by using AM.

The original component was designed keeping in mind the design constraints of the conventional pressure die casting manufacturing process. Taking into consideration, the design freedom provided by AM, we redesigned the entire bracket using Generative Design methodology and applying DfAM (Design for AM) principles.

This resulted in a highly optimized design that was not only 12% lighter and 18% cheaper, but also 25% stronger, in terms of its maximum load-bearing capacity. Finally, an elaborate process was set up for batch production. Please feel free to reach out to us to discuss such innovative cost-saving design/manufacturing ideas for your product.

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Amit Aware

Founded “AMISON Engineering” to cater industry need for design and manufacturing services for conventional and Additive manufacturing technologies.