Page 37 - 3D Metal Printing Fall 2017

Q&A 3D
with re-igniting a past manufacturing line. So, too, when it comes to mass cus- tomization, especially medical implants. Furthermore, instances occur when multi- ple parts that fit into the build envelope are customized simultaneously. When adding standard or common tooling, cost reduction can be significant as compared to the amount of CNC programming needed to machine each part separately.
Lastly, if users find a path forward for 3D metal printing in a production set- ting, benefits arise from qualifying multi- ple parts simultaneously. This can spread out the nonrecurring engineering costs over multiple parts, making the cost-per- part less expensive.
Question:
What makes my part a candidate for performance optimization using 3D printing?
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Answer:
Performance optimization serves as 3D metal printing’s niche. Many times part designs remain bulky due to costs for adding setup and machining sur- faces. Here, weight reduction becomes a performance-optimization benefit. Using structural optimization on bulky brackets and housings reduces the buy:fly ratio while maintaining the same stiffness and functionality. The comple- mentary growth of geometry optimiza- tion, paired with 3D metal printing, will continue to expand these opportuni- ties. In industries where weight reduc- tion is critical, such as aerospace, cost- saving opportunities range from thousands to tens of thousands of dol- lars per pound.
Thermal and fluid optimization func- tions similarly to structural optimization, where unique geometries can open the
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design space for thermal and fluid com- ponents. 3D printing makes optimizing to maximize or minimize surface area easier, which simplifies the build of com- plex geometries. Also, depending on the application, the rough surface finish of 3D-printing technologies acts as an advantage for heat transfer. In fluid opti- mization, parts once line-drilled now can have organic, curved cavities, allowing for less pressure drop and less turbulent flow.
Finally, remember that while applying 3D metal printing can be frustrating because it is not a fix-all manufacturing solution, the potential benefits are many. At companies where engineers, design- ers and procurement understand where and when it makes sense to apply the technology, 3D printing significantly impacts leadtime, cost and geometric optimization. 3DMP
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