3d Printing For Manufacture A Basic Design Guide Download Original
3d Printing For Manufacture A Basic Design Guide Download Original
3d Printing For Manufacture A Basic Design Guide Download Original
Introduction 3
3D printing fundamentals 4
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3D printing fundamentals
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3D printing processes for manufacture
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Introducing Selective Laser Sintering (SLS)
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Introducing Digital Light Processing (DLP)
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Introducing Fused Deposition Modelling (FDM)
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Introducing Direct Metal Laser Sintering (DMLS)
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Design considerations for 3D printing
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1 A word or two about layers and supports...
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Design considerations for Selective Laser Sintering (SLS)
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What are the main design rules?
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Design considerations for Digital Light Processing (DLP)
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What are the main design rules?
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Design considerations for Fused Deposition Modelling (FDM)
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What are the main design rules?
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Usar nervuras devido aos empinamento
■ Warping due to heat is not usually a problem
with FDM parts, but may occur in thin wall
sections. This should be prevented by using
ribs, similar to those used in an injection
moulding.
■ Holes under 3mm in diameter should be drilled
out to ensure their accuracy.
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Design considerations for Direct Metal Laser Sintering
(DMLS)
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1 What are the main design rules?
o
x ■ Support for downward facing surfaces is a
major issue in DMLS part design. For a
general introduction, see page 11. Because
the support material in DMLS parts is made
of the same material as the rest of the
component, removal usually involves
significant machine time.
! Like other processes (FDM - see page 18)
DMLS can build surfaces at an angle without
2 supports (1). The angle will differ with each
material:
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■ Another consideration for DMLS is the
strength of the part as it builds. The
process involves coating newly built
surfaces with a layer of powder, and this is
achieved by drawing a blade over the part.
This blade can connect with the top
surface, so any weak geometry may be
damaged (1).
The solution to this possible problem is to
1 avoid long vertical openings by bridging
them at frequent intervals (2).
As a general rule, the vertical height of a
section of geometry should not be more
than 8 times the width of the part (3).
It is good design practice to drag a
dynamic section up through your CAD
model as the design progresses. This will
simulate the vertical building process and
will allow you to see if there will be any
weak areas during the build itself.
■ It is good to avoid any sharp edges in the
2 design, particularly vertical points.
■ Thick sections should be avoided as the
heat build up in these areas could damage
or distort the part as a whole. This is
1
particularly true if thin areas are placed
next to thick ones.
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■ The removal of the part from the build
platform is another significant issue in the
DMLS process as it involves wire erosion
or Electrical Discharge Machining (EDM).
1 In this process, discharges of electrical
current take place between a wire
electrode and the DMLS platform in a
bath of dielectric liquid, causing material
to be removed. It is slow and uses a
considerable amount of power.
Consequently, anything that can be done
to make it more useful is a positive move.
One way to do this is to include the
cutting path (which is similar to a cheese
wire) in the design of the part, as it will
create a well defined surface (1).
If the cutting path is considered as part of
the design process, the components can
be arranged on the build platform to
minimise the need for supports and utilise
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the cutting path as part of the part
construction (2).
■ Where possible, design parts to be
vertically oriented on the build platform
(2) to make the most use of the space
available.
■ Finally, consider the finishing of your part
when working on the detailed design. It is
possible to polish even the most complex
geometry with deep grooves and holes,
but they should be avoided.
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In summary
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Contacts and further information
Plunkett Associates
(www.plunkettassociates.co.uk).
Plunkett Associates cover all prototyping and
manufacturing solutions, from CNC machining to
injection mould tooling and all the additive layer
based processes that fall under the popular
heading of 3D printing. As it says on their website
‘We get things made’.
3TRPD
www.3trpd.co.uk
3T specialise in SLS and DMLS, and are the experts
when it comes to laser sintered parts.
EnvisionTEC
www.envisiontec.com
EnvisionTEC developed the first DLP systems and
remain the experts.
Stratasys
www.stratsys.com
Stratasys produce some of the best, professional
FDM machines.
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About the author
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