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DfAM Lab: 3D CAD Modeling & Printing

The lab activity focuses on Design for Additive Manufacturing (DfAM), where students will convert 2D parts into 3D CAD models and evaluate them using a DfAM worksheet. They will analyze and optimize the designs to enhance manufacturability and then prepare the models for 3D printing, documenting the process and results. The final deliverables include STL files, print results, and a summary of findings.

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Deepak Panghal
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9 views6 pages

DfAM Lab: 3D CAD Modeling & Printing

The lab activity focuses on Design for Additive Manufacturing (DfAM), where students will convert 2D parts into 3D CAD models and evaluate them using a DfAM worksheet. They will analyze and optimize the designs to enhance manufacturability and then prepare the models for 3D printing, documenting the process and results. The final deliverables include STL files, print results, and a summary of findings.

Uploaded by

Deepak Panghal
Copyright
© All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd

Lab Activity 06 March, 2025 : 2hrs.

Design for Additive Manufacturing (DfAM)

Objective:​
The objective of this lab is to understand the principles of Design for Additive Manufacturing.

Students must convert the three nos. 2D parts (Annexure A) into 3D CAD models and assess
them using the DfAM worksheet (Annexure B) from “The Design for Additive Manufacturing
Worksheet by Joran W. Booth1 et al. Based on the evaluation, they should apply primary or
intermediate DfAM principles to refine the CAD models, if necessary. The finalized models
should then be converted into STL files and printed using the FDM printer available in the lab

Part 1: CAD Modeling and evaluation on DfAM worksheet

1.​ Convert the provided three parts (orthographic views) , Annexure A, into 3D CAD
models using any preferred CAD software (SolidWorks, Fusion 360, CATIA, or
equivalent).
2.​ Ensure proper geometric accuracy and dimensional consistency with the provided views.
3.​ Asses the parts as per DfAm worksheet, Annexure B.

Part 2: DfAM Analysis & Design Optimization and generate STL file

1.​ Analyze the parts using primary or intermediate levels of Design for Additive
Manufacturing (DfAM) principles.
2.​ Identify design modifications to enhance manufacturability while reducing material waste,
print time, and support dependency etc..
3.​ Implement changes based on the analysis and redesign the CAD models accordingly.
4.​ Export the CAD models in STL file format, ensuring appropriate mesh resolution suitable
for FDM printing.

Part 3: 3D Printing & Process Parameter Optimization

1.​ Prepare the optimized STL files for 3D printing using an FDM printer.
2.​ Select appropriate process parameters for best possible print quality, considering:
○​ Layer Height
○​ Infill Density
○​ Print Speed
○​ Temperature Settings
○​ Support Structures etc..
3.​ Print the final optimized parts and document the results with:
○​ Print Time & Material Usage
○​ Surface Finish & Structural Integrity
○​ Comparison of Original vs. Optimized Designs etc.
4.​ Summarizing your findings, including snapshots of CAD models, STL files, and printed
parts.
Annexure A

General guidelines

●​ All dimensions are in mm


●​ Take necessary values as per understanding for the missing values, characteristics,, if
any.

Part 1
Part 2

Part 3
Annexure B
The DfAM worksheet is designed for novices and intermittent users of additive
manufacturing technologie

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