Additive manufacturing services are unlocking new design possibilities that traditional methods simply can’t match. However, to realize the full value of these advanced techniques, it’s critical to follow best practices for Design for Additive Manufacturing (DFAM). At 3D Parts Unlimited, we help our clients optimize their designs by leveraging cutting-edge 3D printing technologies and deep industry knowledge. To guide your next project, we’ve compiled six practical DFAM design tips that will help you take full advantage of what additive manufacturing has to offer.
1. Choose Materials That Align with the Part’s Mechanical Needs
Not all 3D printing technologies are compatible with every material, and each material offers different mechanical properties. Whether your application requires heat resistance, chemical resistance, high strength, or flexibility, selecting the right material upfront is key.
For example, if your part requires greater impact resistance, you could select Nylon PA 11 or Thermoplastic Polyurethanes (TPU). Or if your part requires higher flexibility, you could use TPUs, Polyproylenes, or certain liquid polymers that allow you to achieve certain Shore A hardnesses depending on your application and how much flexibility you need.
2. Select the Additive Manufacturing Process Before Designing the Part
The design of your part should be tailored to the capabilities of the chosen additive manufacturing process. Processes like fused deposition modeling (FDM), selective laser sintering (SLS), Multi Jet Fusion (MJF), direct metal laser sintering (DMLS), and continuous liquid interface production (CLIP) all come with their own strengths and limitations.
If you are designing for FDM, for instance, you want to minimize your overhangs and optimize features for support. For example, if you just need a hole to route wires through, you could use a teardrop shape instead of a circular hole – this shape avoids the need for a support structure, and therefore eliminates the need for post-processing to remove the supports. On the other hand, if you’re designing for plastic powders, you don’t really need to worry about overhangs or support because the powder is the support.
Knowing your process in advance allows you to design with those constraints and capabilities in mind, resulting in faster lead times and fewer design revisions.
3. Consider Part Consolidation for Assemblies Where Possible
One of the biggest advantages of 3D printing over other manufacturing processes is the ability to consolidate multiple parts into a single printed assembly. This not only simplifies manufacturing but also enhances part performance by reducing points of failure and eliminating fasteners or welds.
By consolidating parts in your design, you can significantly reduce assembly time and inventory complexity.
4. Use Lattice Structures to Reduce Weight
Traditional manufacturing makes it difficult to achieve lightweight, strong components. However, 3D printed lattice structures enable the creation of internal geometries that significantly reduce weight while maintaining mechanical strength.
Lightweighting is particularly important in industries like aerospace, where every gram counts. By incorporating lattice structures into your design, you can reduce material usage, improve thermal performance and load distribution, and reduce cost.
5. Design Integrated Internal Channels and Features That Are Easy to Post-Process
Additive manufacturing allows you to design parts with integrated internal features like cooling channels, wire guides, and fluid pathways – something that’s difficult or impossible with traditional methods. However, it’s crucial to ensure these features are accessible for post-processing, such as cleaning or support removal.
In selective laser sintering and Multi Jet Fusion, powder removal must be considered when designing enclosed spaces. For example, when designing a blind hole, consider if it could instead be made a through hole, or connected with another hole, to allow for easier powder removal.
6. Consider the Tolerances of the Printer
Every 3D printer has its own tolerance limitations depending on the technology and material used. Ignoring these tolerances can lead to interference issues, poor fits, or functional failures.
No matter what part you’re printing, the tolerances for every dimension on the part are going to be the tolerance of the printer, not what is specified on the PDF print. It’s important to consider the capabilities of the specific printer and printing process when designing a part to make sure the desired tolerances can be met.
Ready to Redefine Your Parts? We’re Ready to Help.
Design for Additive Manufacturing is more than just adapting existing designs to be 3D printed; it’s about rethinking how parts are conceptualized, optimized, and produced. From choosing the right material and process to exploiting the benefits of 3D printed lattice structures and part consolidation, these design tips can elevate your next project.
Whether you’re developing 3D printed prototypes, fixtures, or mission-critical aerospace parts, the team at 3D Parts Unlimited is here to guide you every step of the way. Our expertise in industrial 3D printing and cutting-edge additive manufacturing services ensures your parts are functional, efficient, and ready for production.
Ready to take your designs to the next level? Contact us today to learn how we can help you turn bold ideas into real-world solutions.