Short answer
When designing for additive manufacturing of large components, plan for modularity and develop a robust joining strategy early in the design process.
- Field
- Final Production
- Source
- DigitalCommons@CalPoly (2017)
- Method
- Design and Prototyping
- Evidence
- Strong effect
Designing for modularity enables the creation of components larger than the build volume of additive manufacturing machines. This final production research insight is drawn from a 2017 study published in DigitalCommons@CalPoly. Using Design and prototyping, researchers explored how this design variable affects real-world outcomes. The key design takeaway: When designing for additive manufacturing of large components, plan for modularity and develop a robust joining strategy early in the design process.
Modular Design for Large-Scale Additive Manufacturing
Designing for modularity enables the creation of components larger than the build volume of additive manufacturing machines.
DigitalCommons@CalPoly · 2017
Key Findings
- 01Additive manufacturing machines have limitations in build volume.
- 02Dividing large parts into smaller printable sections is a common workaround.
- 03A robust joining method is crucial for the integrity of assembled parts.
Application
Design takeaway
When designing for additive manufacturing of large components, plan for modularity and develop a robust joining strategy early in the design process.
How to apply
When designing a large product intended for additive manufacturing, break it down into smaller, manageable sections that fit within the machine's build volume. Design integrated features for a strong and reliable joining mechanism between these sections.
Project actions
- 01Clearly define the requirements for the joining method based on the intended use of the final part.
- 02Explore various joining techniques (e.g., mechanical fasteners, welding, adhesives) and evaluate their suitability for the specific AM material and application.
Method & Evidence
Variables
Strengths & Limitations
Strengths
- +Addresses a real-world limitation in additive manufacturing.
- +Involves collaboration with an industrial partner (LLNL).
Limitations
The developed joining method might not be universally applicable to all metal alloys or all additive manufacturing processes. The long-term durability of the joint under operational stress may also be a limitation.
Reliability & validity
Reliability could be assessed by repeating the joining and testing procedure multiple times. Validity would depend on how well the chosen tests (e.g., tensile strength) reflect the intended functional requirements of the joined part.
Think critically
To what extent does the chosen joining method compromise the structural integrity or aesthetic quality of the final assembled part?
Design Principles
"Design for Disassembly and Reassembly: Components can be designed to be printed in sections and then reliably joined to form a larger, functional whole."
This approach overcomes a significant limitation in metal additive manufacturing, allowing for the production of larger, more complex parts. It opens up new possibilities for product design and manufacturing, particularly in industries requiring large structural components.
What This Means for Your Design
If you want to 3D print something bigger than your printer can handle, you need to design it in pieces and figure out how to stick those pieces together strongly.
How to use in your project
- 1.Reference this research when discussing the limitations of current manufacturing technologies and how design strategies can overcome them.
- 2.Use the concept of modular design to justify breaking down a larger project into smaller, printable components.
Add to My Project
Quick Cite
Paragraph starter
The challenge of overcoming the build volume limitations in additive manufacturing necessitates a modular design approach. By dividing large components into smaller, printable sections and developing a robust joining method, it becomes possible to produce significantly larger parts than the machine's capacity would otherwise allow. This research highlights the critical role of post-processing design in enabling the fabrication of complex, large-scale components through additive manufacturing.
Source
Questions About This Research
- What does the research say about modular design for large-scale additive manufacturing?
- When designing for additive manufacturing of large components, plan for modularity and develop a robust joining strategy early in the design process. Evidence: DigitalCommons@CalPoly (2017).
- Why does "Modular Design for Large-Scale Additive Manufacturing" matter for design?
- This approach overcomes a significant limitation in metal additive manufacturing, allowing for the production of larger, more complex parts. It opens up new possibilities for product design and manufacturing, particularly in industries requiring large structural components.
- How can designers apply this research?
- When designing for additive manufacturing of large components, plan for modularity and develop a robust joining strategy early in the design process.
- What were the main findings?
- Additive manufacturing machines have limitations in build volume.. Dividing large parts into smaller printable sections is a common workaround.. A robust joining method is crucial for the integrity of assembled parts.
- What research method was used?
- Design and Prototyping.
- How strong is the evidence?
- Evidence strength is rated Strong effect, based on a 2017 journal from DigitalCommons@CalPoly.
- What should I do differently in my next project?
- When designing a large product intended for additive manufacturing, break it down into smaller, manageable sections that fit within the machine's build volume. Design integrated features for a strong and reliable joining mechanism between these sections.
- What are the limitations?
- The effectiveness of the joining method may vary depending on the specific metal alloy, the printing process used, and the intended application of the assembled part.