From Rapid Prototyping to Quick-Turn Production Day 2: Design Considerations for Manufacturability

Course Content Intent Focus What’s available Design considerations Production processes Focus Industrial-grade AM Concept  low-volume production Photo courtesy of 3T RPD 2

Path to Production Demands Quantity Product Development Process Models Prototypes Patterns Tooling Mfg Aids Production Repair End of Life Product Development Process Development Production 3

Path to Production Molding Machining AM Product Development Process Models Prototypes Patterns Tooling Mfg Aids Production Repair End of Life AM Product Development Process Development Production 4

Clarify Criteria & Goals Demands For each phase What is mandatory? What is good to have? What is unnecessary? Criteria Time Cost Quality Performance 5

Materials General AM Machining Molding Broad but shallow Mimic/match Lack qualifying data Machining Broad and deep Molding 6

Materials - AM SL When to use Photopolymers Dozens of options At best, mimic ABS, PC, PP When to use Need balanced solution Can accept properties Models Prototypes Production 7

Materials - AM SLS When to use Thermoplastics Primarily nylon Some high temp Some filled When to use Functional/stable materials Prototypes Functional prototypes Production 8

Materials - AM FDM When to use Thermoplastics Five polymers When to use Functional/stable materials Prototypes Functional prototypes Production 9

Materials - AM DMLS When to use Metals “Real” materials Six alloys Prototypes Functional prototypes Production 10

Decision Point Need spec materials? Yes (plastics) Yes (metals) Molding Yes (metals) Machining/casting 11

Design - DFM Applies to all AM Molding Machining Fewer rules Most for time, cost, quality Some for secondary processes But specific to technology 12

Design – AM (production) Leverage design freedoms Optimize E.g., Consolidation Eliminate E.g., draft Perform E.g., adjust for properties 13

Design – AM (prototype) Leverage design freedoms (as long as you can) Optimize E.g., Consolidation Eliminate E.g., draft Perform E.g., adjust for properties 14

Conclusion AM is different/unique Machining ≠ molding Materials Design Process Machining ≠ molding Understand differences Leverage Counter 15

Join Us for Day 3 What’s Next After 3D Printing? A look a time, cost, quality and operations For process selection after prototyping 16

Questions Please post your questions in the live online chat and I will answer them there! Todd Grimm T. A. Grimm & Associates (859) 331-5340 Todd.Grimm@tagrimm.com 17

About Proto Labs Proto Labs is a leading technology-enabled, quick-turn manufacturer of custom prototypes and low-volume production parts. Proto Labs’ proprietary software translates 3D CAD models into instructions for rapid manufacturing processes that include injection molding, CNC machining and 3D printing. 18

About Proto Labs cont. Automated, online quoting system analyzes the CAD model, proposes revisions to improve manufacturability, and provides a quote within 1-3 hours.   Rapid Injection molding is used for custom prototypes, bridge tooling and low-volume production runs of 25 to 10,000+ plastic, metal, and liquid silicone rubber parts. Parts are made in 1-15 days. Three-axis milling and CNC turning is used for engineering-grade plastic and metal parts in quantities of 1 to 200+. Parts are made in 1-3 days. 3D printing is used for plastic and metal parts with complex geometries in quantities of 1 to 50+. Parts are made in 1-7 days. 19