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Design for Additive Manufacturing

In Additive Manufacturing, Design for Manufacturing (DFM) plays a crucial role in optimizing the production process. By integrating DFM principles, we ensure that your designs are tailored for additive technologies, maximizing efficiency and performance. This involves leveraging the unique capabilities of 3D printing, such as creating complex geometries and lattice structures, which are not feasible with traditional manufacturing methods. Our expertise in DFM helps you reduce material usage, minimize waste, and achieve faster production cycles, ultimately leading to cost-effective and high-quality parts.

• Optimize Part Orientation

  Minimize Supports: Orient parts to minimize the need for support structures, which can reduce material usage and post-processing time. For example, orienting a complex part like a lattice structure horizontally may require fewer supports compared to a vertical orientation.

  Enhance Surface Quality: Position the part to optimize the surface finish on critical areas. For instance, orienting the functional surface of a prosthetic limb component upward can ensure a smoother finish without support marks.

• Design for Minimal Post-Processing

  Integrated Features: Design features like threads or snap-fits directly into the part to avoid additional machining or assembly. For example, embedding threaded inserts into a custom connector part reduces the need for manual thread cutting.

  Reduce Supports in Critical Areas: Place supports in non-visible or non-functional areas to minimize post-processing impact. For instance, designing a shoe midsole with support structures on the internal surfaces avoids affecting the external aesthetics.

• Lattice Structures

  Lattice and Honeycomb Structures: Use lightweight lattice or honeycomb structures to reduce material usage and print time while maintaining strength. For example, designing a drone frame with internal lattice structures can significantly reduce weight without compromising rigidity.

  Variable Density: Employ variable density infills to optimize the balance between weight and strength. For instance, a helmet liner can have denser structures in high-impact areas and lighter structures elsewhere.

• Functional Integration

  Combine Multiple Parts: Integrate multiple components into a single printed part to reduce assembly time and improve structural integrity. For example, a complex assembly like a multi-functional tool can be printed as a single piece with moving parts.

  Embedded Channels: Design internal channels for cooling, wiring, or fluid flow directly into the part. For example, printing a manifold with internal fluid channels can eliminate the need for post-processing drilling.

• Material Optimization

  Select Appropriate Resins: Choose resins that meet the mechanical and thermal properties required for the application. For instance, using a high-strength resin for load-bearing parts like a bicycle frame ensures durability and performance.

  Tailor Material Properties: Use Carbon's proprietary resins with specific characteristics such as elasticity for flexible components like gaskets or high impact resistance for protective gear.

• Surface Finish and Accuracy

  Design for Surface Quality: Plan for the best possible surface finish by avoiding overhangs and steep angles where supports are necessary. For example, designing an eyewear frame with gentle curves reduces the need for support structures, leading to a smoother finish.

  Dimensional Accuracy: Account for the dimensional accuracy and tolerance levels of Carbon DLS technology. For instance, designing an interlocking mechanism with appropriate clearances ensures a proper fit without post-processing adjustments.

• Simulation and Iteration

  Use Design Engine Tools: Leverage Carbon's Design Engine to simulate and optimize the part design, ensuring manufacturability and performance. For example, running simulations on a complex mechanical part can identify potential stress points and optimize the design for durability.

  Iterative Prototyping: Utilize the rapid prototyping capabilities of Carbon DLS to iterate and refine designs quickly. For instance, producing multiple iterations of a medical device component allows for thorough testing and refinement before final production.

• Efficient Packing and Printing

  Optimize Build Volume: Arrange parts within the build volume efficiently to maximize the number of parts printed per run. For example, nesting smaller components around larger parts can fully utilize the printer's capacity.

  Batch Production: Design parts that can be efficiently produced in batches, reducing overall production time. For example, designing a series of small clips or fasteners that can be printed simultaneously in a single build.