Title Slide Design for Additive Manufacturing (Fabrico Aditivo) Rui Miguel
Antunes Subtil Rodrigues – Nº 2182304 Docente: Pedro Custódio
Universidade - UC: Fabrico Assistido por Computador
Slide 1: Objectives
Understand what Additive Manufacturing (AM) is
Review its historical development
Explore industrial applications and benefits
Compare with traditional manufacturing
Learn design principles for AM
Slide 2: What is Additive Manufacturing?
Also known as 3D Printing
Builds parts layer-by-layer from digital models
ISO 52900: Defines 7 process categories
o Powder Bed Fusion, Material Extrusion, Binder Jetting, etc.
Offers new design and production possibilities
Slide 3: Historical Background
1860: Photo-sculpture by François Willème
1981: Hideo Kodama – Early photopolymerization
1984: Charles Hull – Stereolithography
1989: Powder Bed Fusion (Deckard & Beaman)
2010: ASTM F42 defines standard categories
Slide 4: Categories of AM
Powder Bed Fusion (PBF)
Directed Energy Deposition (DED)
Material Extrusion
Vat Photopolymerization
Binder Jetting
Sheet Lamination
Material Jetting
Slide 5: AM in Industry
Aerospace: weight savings, custom geometries
Medical: patient-specific implants
Automotive: prototyping, customization
Consumer products: low-volume parts
Slide 6: Benefits of AM
Complexity for free: costs not tied to geometry
Lot size independence: efficient small batch production
Lightweight and optimized parts
Faster prototyping cycles
Slide 7: Challenges to Adoption
Technological: build size, material limits
Organizational: lack of expertise
Market: high costs, unclear ROI
Slide 8: Comparison with Traditional Manufacturing
Feature Conventional Additive
Tooling Required Not required
Customization Difficult Easy
Material use Subtractive Additive
Design freedom Limited High
Slide 9: Design Freedom
Complex geometries without added cost
Consolidation of parts
Lightweight lattice structures
Slide 10: Design Guidelines (Overview)
Layer-by-layer constraints
Material-process compatibility
Anisotropy and residual stresses
Minimizing support structures
Slide 11: Stair-Step Effect
Layer height affects surface quality
More pronounced in vertical surfaces
Reduced by smaller layer thickness
Slide 12: Material-Process Relationship
Not all materials fit all processes
Metals, polymers, ceramics, biomaterials
Example: PBF needs powdered feedstock
Slide 13: Anisotropy and Internal Stresses
Properties vary with build direction
Laser fusion can cause thermal gradients
May lead to warping, cracking
Slide 14: Support Structures
Necessary for overhangs and stability
Influence post-processing time and cost
Strategies to reduce:
o Optimal orientation
o Alternative support methods
Slide 15: Design for Function
Focus on the part’s purpose
Form follows function
Remove unnecessary material
Slide 16: Function Integration
Combine multiple parts into one
Reduce assembly needs
Improve reliability
Slide 17: Part Orientation
Affects support needs and surface quality
Best orientations minimize support
Consider heat distribution
Slide 18: Material Minimalism
Less volume = shorter build time
Important for cost efficiency
Use hollow or lattice structures
Slide 19: Hybrid Parts
Combine AM with conventional methods
Example: Conventional base + printed insert
Best of both worlds
Slide 20: Reference Design Values
Wall thickness: >2x layer height
Minimum hole diameter: process dependent
Max overhang angle: ~45° (varies)
Use ISO/ASTM 52911-1 for guidance
Slide 21: AM Workflow
1. CAD modeling
2. STL export
3. Slicing
4. Machine setup
5. Build process
6. Post-processing
Slide 22: Generative Design & Topology Optimization
Design generated from performance goals
Software-driven geometry creation
Ideal for lightweight and efficient designs
Slide 23: Conclusion
AM enables freedom and innovation
Requires process-aware design
Potential is vast, but not without challenges
Designers must adapt to fully leverage it
Slide 24: Q&A Thank you! Questions?