Automotive Engineering - August 2022 - 24

Optimizing design for
additive manufacturing
ADDITIVE MANUFACTURING FEATURE
Maximum build size
This might seem like an obvious, but all 3D printers -
whether desktop, mid-range or full production systems
- have a maximum build size. Remarkably this is often
overlooked. Across 3DPrintUK's fleet of industrial-scale 3D
printers our maximum build sizes are: 300 x 300 x 600
mm (for SLS PA12); 350 x 255 x 350 mm (for MJF PA12),
and 180 mm x 120 mm x 120 mm (for SLS flexible TPU).
3DPrintUK will always position parts in a build to get
Engineers working within the PBF process need to consider the impact of holes
and channels in the part design and heat exposure during the build process.
they design into parts, especially when it comes to holes and channels
running through them. The nature of the PBF process comes into play
here, specifically the amount of heat that parts are exposed to during
the build process. Thus, holes and channels with small diameters can
result in fused powder within them.
To prevent this, the recommendation is to design them greater
than 3 mm. For long internal channels over 50 mm (1.97 in.) the same
problem applies. It can be difficult to remove all of the powder, therefore
diameters greater than 5 mm are recommended for internal
channel features. The same rule applies to curved holes.
the best possible outcome - no matter the original
orientation of the file. The only exception to this is if a
client locks the orientation while placing the order.
Designing for 3D printing is a vital facet of successful
outcomes with the AM technology. Hopefully this
overview will provide a useful primer for anyone coming
to the technology for the first time or some fresh
insight to anyone working with the technologies on
new products or parts.
Nick Allen is managing director of 3DPrintUK, a U.K.-based
specialist in low-volume production using powder bed fusion
(PBF) 3D printing systems with polymer materials. The
company bridges the void that exists between prototyping
and injection molding. www.3dprint-uk.co.uk
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September 6-8, 2022
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Powertrains,
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Automotive Engineering - August 2022

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