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

2. 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

3. 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

4. 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

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

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

7. 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

8. 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

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

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

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

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

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

14. 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

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

16. 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

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

18. 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

19. 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 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