Design for Additive Manufacturing (DFAM)

Ultimately, 3D printing designs are created using CAD software and then prepared for 3D printing with a slicer that divides the model into layers. This software allows a designer to create 2D and 3D designs.

Topology optimization mathematically configures a design and material distribution to most efficiently meet predetermined parameters such as size and strength.

“So what topological optimization is saying is I've got these loads and I'm going to remove material in order to minimize the amount of material that I have. And it's actually a fairly simple process of putting a load on, looking where the stresses are, where there's no stresses, reduce the stiffness and the density, and keep doing that until you get holes and your part is going to work.”

–Eric Miller, of Phoenix Analysis & Design Technologies, discussing the difference between topology optimization and generative design with Additive Manufacturing Media’s Stephanie Hendrixson.

When designers include channels in their parts, they often forget that these features don’t have to be bound to the shape of a simple round hole. With 3D printing, holes and channels can be any shape that provides proper support for the build.

Source: Creating Designs That 3D Printing Experts Love

Parts that look sharp shouldn’t necessarily have sharp edges. In fact, with 3D printed parts, it’s better to look smooth. Whenever possible, use interior radii for edges and corners. That smooth contour not only has a great look, but it has the benefit of relieving the stresses that build up during the printing process.

Source: Creating Designs That 3D Printing Experts Love

Lightweighting is producing a part that weighs less than a similar part made through another manufacturing process. Additive manufacturing’s ability to provide complex geometries with internal passages often results in a lighter part compared to a conventionally manufactured part. More negative space means less weight.

This microturbine is an example of a lightweighting success.

Complex geometries are shapes and designs that are intricate or could be difficult to create with conventional manufacturing options. For example, a part that requires interior coolant delivery will need channels that not only deliver fluid, but also allow for the fluid to exit the part. With conventional manufacturing, this could demand the production of multiple parts that must then be assembled or machined. However, additive manufacturing can produce a single part with built-in channels that can be in almost any shape, not just round holes.

An example of a complex geometry made possible only by additive manufacturing is this heat exchanger that uses gyroids for better cooling.