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How can you improve your 3D model design with DFAM principles?

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3D printing is a powerful technology that can create complex and customized parts, but it also comes with some challenges and limitations. One of them is the high cost and waste of materials, especially when using metal or resin-based printers. To optimize your 3D printing process and reduce material usage, you need to design your 3D models with DFAM principles in mind.

DFAM stands for Design for Additive Manufacturing, and it is a set of guidelines and best practices that help you create 3D models that are suitable for 3D printing. DFAM principles take into account the capabilities and constraints of the 3D printing technology, such as layer thickness, orientation, support structures, overhangs, and infill patterns. By applying DFAM principles, you can improve the quality, performance, and efficiency of your 3D printed parts, and save time and money in the long run.

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Swapnil Sansare

India Design Mark Award Winner | Past Vice President IAMF | 3D Printing Evangelist | CEO & Founder | On Demand…
Duann Scott

Bits to Atoms + CDFAM Computational Design Symposium Series
Shrinidhi Bhat

Application Engineer @ amace solutions | Metal Additive Manufacturing | LPBF | Process Development | Technology…

1 Understand your printer and material

The first step to improve your 3D model design with DFAM principles is to understand the characteristics and specifications of your 3D printer and the material you are using. Different 3D printing technologies, such as FDM, SLA, or SLS, have different advantages and disadvantages in terms of speed, accuracy, resolution, and surface finish. Similarly, different materials have different properties, such as strength, flexibility, durability, and thermal resistance. You need to choose the right printer and material for your project, and design your 3D model accordingly.

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2 Simplify and optimize your geometry

The second step to improve your 3D model design with DFAM principles is to simplify and optimize your geometry. This means reducing the complexity and size of your 3D model, and avoiding unnecessary features that can increase material usage and printing time. For example, you can use hollow or lattice structures instead of solid ones, or use fillets and chamfers instead of sharp edges and corners. You can also use Boolean operations to merge or subtract parts, or use parametric modeling to create scalable and adaptable designs.

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Jayant Mathur

Senior Program Specialist - Digital and Immersive Technologies
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Also consider the impact leveraging multiple materials or printed assemblies may have on "optimizing" your design. Joints for example, greatly benefit from a transition of soft and hard materials and are a great example of part consolidation as well.

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3 Orient and support your model

The third step to improve your 3D model design with DFAM principles is to orient and support your model. This means choosing the best position and angle for your 3D model on the print bed, and adding support structures if needed. The orientation and support of your model can affect the quality and strength of your 3D printed part, as well as the amount of material and post-processing required. For example, you can orient your model to minimize overhangs and bridges, or use custom or tree-like supports to reduce contact points and scars.

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4 Choose the right infill and layer settings

The fourth step to improve your 3D model design with DFAM principles is to choose the right infill and layer settings. This means selecting the appropriate density and pattern for the internal structure of your 3D model, and the optimal thickness and number of layers for the external surface. The infill and layer settings can affect the weight, strength, and appearance of your 3D printed part, as well as the printing time and material consumption. For example, you can use a low infill percentage and a honeycomb or gyroid pattern for lightweight and strong parts, or use a high layer height and a spiral vase mode for smooth and fast prints.

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Duann Scott

Bits to Atoms + CDFAM Computational Design Symposium Series
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While this infill strategy speaks primarily to the settings of a desktop FDM 3D printer, it alludes to the way in which a machine and parameters used can affect the properties of the material, and performance of the part.

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5 Test and iterate your design

The fifth step to improve your 3D model design with DFAM principles is to test and iterate your design. This means verifying and validating your 3D model before printing, and making adjustments and improvements based on the feedback and results. You can use various tools and methods to test and iterate your design, such as simulation software, slicing software, print preview, and prototype printing. By testing and iterating your design, you can avoid errors and failures, and optimize your 3D model for the best performance and quality.

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6 Learn from others and share your experience

The sixth and final step to improve your 3D model design with DFAM principles is to learn from others and share your experience. This means seeking inspiration and guidance from other 3D printing enthusiasts and experts, and contributing to the 3D printing community with your own projects and tips. You can use various platforms and resources to learn from others and share your experience, such as online forums, blogs, podcasts, videos, courses, and books. By learning from others and sharing your experience, you can expand your knowledge and skills, and discover new ideas and possibilities for your 3D printing projects.

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Swapnil Sansare

India Design Mark Award Winner | Past Vice President IAMF | 3D Printing Evangelist | CEO & Founder | On Demand Manufacturing Expert
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Harnessing DFAM (Design for Additive Manufacturing) reshapes design paradigms. Consider nature's genius: a honeycomb's lightness and strength. In 3D printing, bespoke designs flourish. Instead of generic tools, picture one crafted to fit a user's hand perfectly. Combining parts into a unified print reduces material use and eliminates joins. Opt for intricate lattices over solid blocks to save material without compromising durability. With DFAM's flexibility, boundaries fade, offering vast creative latitude. Essentially, if it's conceivable, 3D printing brings it to life.

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Shrinidhi Bhat

Application Engineer @ amace solutions | Metal Additive Manufacturing | LPBF | Process Development | Technology Innovation |
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Design for additive manufacturing is always about designing for value-optimized parts. As a designer, one's aim should be to design something that can be printed faster, cheaper, and better. Delivering the right material properties, design options, and business value should be the overall essence of DFAM.

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7 Here’s what else to consider

This is a space to share examples, stories, or insights that don’t fit into any of the previous sections. What else would you like to add?

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Michael John Sweers

Founder of MTL | Democratizing Design in Large Scale Additive Manufacturing, 3D Printing and Robotics for Industry 4.0
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Assess Cost-Efficiency through DFAM Principles Design for Additive Manufacturing (DFAM) is not just about making a 3D model printable; it's about optimizing the design for both performance and cost. DFAM principles can serve as a critical framework for assessing the cost-efficiency of your 3D printing projects, helping you to achieve the best results without unnecessary expenditures. For example: -Material Optimization -Minimizing Support Structures -Efficient Design Features -Batch Printing and Nesting -Lifecycle Thinking

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How can you improve your 3D model design with DFAM principles?

1

2

3

4

5

6

7

1 Understand your printer and material

2 Simplify and optimize your geometry

3 Orient and support your model

4 Choose the right infill and layer settings

5 Test and iterate your design

6 Learn from others and share your experience

7 Here’s what else to consider

3D Printing

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How can you improve your 3D model design with DFAM principles?

1

2

3

4

5

6

7

1 Understand your printer and material

2 Simplify and optimize your geometry

3 Orient and support your model

4 Choose the right infill and layer settings

5 Test and iterate your design

6 Learn from others and share your experience

7 Here’s what else to consider

3D Printing

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