Marketing Flow Chart 270611

8/4/2019 Marketing Flow Chart 270611

1/20

Current designsMake it so the buildworks.

New designsOptimise for best useof SLM.

Traditional manufacturing process Additive manufacturing process

Design rules for; Casting Machining Sheet metal Injection moulding

A compromise of what is allowable by customer will put the design somewhere along this line.

Improved by MTT RecommendationsImproved by MTT minimum Requirements


2/20

http://viewer.zmags.com/publication/1f2ee068#/1f2ee068/38

Internal mesostructure e.g. honey comb, lattice, etc

Improve material usage and build time.Reduce stress. Reduce risk of build failure.

Only put material around constrains(location holes, critical surfaces, etc.)

Increased impact on other components that itinterfaces with.

http://www.emeraldinsight.com/content_images/fig/1560160406012.png

Design for Subtractive manufacture

Renishaw example, J. Pullin

New designs Optimise forbest use of SLM. Review designconstraints rather than existinggeometry (as this will likely have

carry over design rules fromtraditional process)

Design for Additive manufacture
http://viewer.zmags.com/publication/1f2ee068http://www.emeraldinsight.com/content_images/fig/1560160406012.pnghttp://www.emeraldinsight.com/content_images/fig/1560160406012.pnghttp://viewer.zmags.com/publication/1f2ee068


3/20

Customer reviews MTT flowchart to assess whether there chosen product meets the minimum requirements

Customer supplies CAD and Critical Characteristics Form to initial MTT process

MTT check and confirm data is complete and acceptable

MTT Engineering review data and visually update with colour coding, annotations and illustrated standarddesigns to feedback to the customer on their design. Feedback on Requirements and Recommendations

Customer updates in accordance to at least the Requirements

Customer re-submits CAD

MTT check and confirm data is corrected and build preparation can start

MTT carry out build preparation (Orientation, Support structure, etc.)

Schedule build and communicate confirmed lead time to customer

From here customer can

see status of job similar toonly shopping. Order

picked, Dispatched, etc

Possibly more fundamentalsuggestions that allow a morecomplete optimisation for bestresults of SLM.

Minimum changes requiredto make SLM build possible


4/20

Can it be modified to optimise its design for SLM

No Yes

Fill out form, attach 3D CAD and 2D drawing

and send to MTT

Please contact MTT to get more information on file

formats and where the Critical Characteristic form can be

downloaded from.

Without out this information we can not fully know your

application requirements and produce a part that meets

your needs and shows the true potential of the SLM

process

Has your part been designed for SLM

There are different designrules for SLM. traditionalmanufacturing process allhave constants that must beconsidered when designing apart

No Yes

If for any reasons during this processthere are recommendations made that

you are not able to implement then it maybe that the finial part may not be

optimised to its full potential. Resulting inincreased material, weight, cost or lead

time

Can you provide MTT with the critical information

needed to produce the best possible part for you.

No Yes

If a 2D drawing is not availablesuit able notes must be added tothe CC Form.All the information is required.We shall not be able to progressuntil we fully understand orapplication

Please contact MTT

Possiblesupporting

document or weblocation

See 3D CAD, 2D Drawing and Critical Characteristics Form details on separate page


5/20

3D CAD, 2D Drawing and Critical Characteristics Form

Part orientation and Surface Roughness

Material allowance / Geometric compensation

Minimum clearance between features

Minimum wall thickness

Chamfers and Radii

Curved Surfaces

Holes

Pilot Drilling Threads Reaming

Engineering

Customer Input

Geometric detail (3D CAD)Function (Non 3D CAD)

Geometric tolerance

Critical Characteristics (C.C)

Current post processes

Current manufacturing method

Priority attributes, why have you chosen SLM?

What would you be prepared to optimise in new design

Weight

Material

Cost

Lead Time (Tool less components)

Surface area / volume ratio


6/20

1. How much is the design influenced by traditional manufacturing guidelines. Design for casting, Design for machined components, etc

2. Which non critical features can be removed so that an unbiased design intent is more clear.

3. What are the fixed constraints in the design. How does it function. How does it interface with other parts or systems. Fixing holes Guiding surfaces Location features

4. Can material be removed to make part more efficient. Use less material, Weigh less, Optimise for strength and stiffness. Be built quicker and more reliably.

5. Can multiply parts be integrated into one component. Some designs may have been broken in to assemblies of separate parts to simplify traditional manufacturing.Can these now be combined, reducing assembly and the need for additional fasteners. Potentially allowing forimproved material optimisation

6. What post processing is required currently

7. What post processing will be required with SLM

New designs Optimise for best use of SLM. Proposed Stages


7/20

Angled position

Adjustable position

Combined parts

Combined parts

Interface with other parts

Remove material

Clamping position

Combined parts

Critical Function

Potential Optimisation

Process Stage 2-5


8/20

1

2

3

4

1

2

3

4

1 2 3 4

Angledposition

Adjustableposition

Clampingposition

Interface withother parts

Combine parts Combine parts Remove

material

Remove

material

Critical Function

Potential Optimisation


9/20

Internal mesostructure e.g. honey comb, lattice, etc

Improve material usage and build time.Reduce stress. Reduce risk of build failure.

Only put material around constrains(location holes, critical surfaces, etc.)

Increased impact on other components that itinterfaces with.

Build Stress vs application Stress Build Orientation for strength


10/20

AM standard features library Potentially 2 lists (1 for Solid modelling, 1 for Mesh modelling)

Functional featuresClampingSurface textures

Material removalLattice modulesConstraint transitions

Material Allowance (Stage 1)Surface finish allowance (down,up and side facing surfaces)Thread cuttingClearance holesPre-assembled parts allowance needed to stop assembly parts welding together

Sector SpecificHigh Surface area designs for heat exchanger designs

How are design tools to be used? Current mechanical CAD - Solid model (Solidworks), Mesh model (Rhino, 3dsMAX) orpre-process (AutoFab)

What are design tools? They should encourage education and re-use of standard building block design features.

How should they be used? The designer needs to have an understanding of the design rules for SLM, in a similar waythat a designer has an understanding of design rules for plastic injection moulding today. The main consideration is buildorientation, so that features can be added in the correct plan and the design can be built with a self supporting topology.

Design tools Standard features library


11/20

C = HIGHEST QUALITY SURFACE AND ACCURACY. The highest quality surface quality and accuracy (see C). Critical geometries are to be identified to

ensure that they are considered in the orientation.

A = QUICKER BUT MORE SUPPORT IS NEEDED

The part can be built in the lowest orientation for speed of build and lim iting cost (see A). Excessivesupport structures and poor surface quality may be the result of this choice.

An average of the first two orientations may be selected where time and cost is not

constrained and the surface quality is not particularly critical (see B). OR A COMBINATION OF

GEOMETRY NEEDS TO BE CONSIDERED.

Total volume of material = support and build = material cost.Support is build material. B is potentially more expensive. (material + cycle time)

Customer designs are notrectangles.if they arecustomers should stick with Subtractive

As soon as designs are more than 1 feature the design needs to work within thechosen build orientation.

Choosing build orientation needs to consider Feature priority (Customer CADinput) and Critical Attribute priority (Customer Non-CAD input).

1 feature

2 features 3 features

Critical Attribute priority Design for cost, Surface quality, or speed


12/20

Notes


13/20

Design for machining. Includes; Undercuts Overhangs

SLM design remove unnecessary features;

Undercuts Overhangs Add large chamfer or radius.

This may be more to do with build process stressthan application stress. Stress concentration atcorner pulls build apart XXX

Separate build sections cometogether at the top causingstress in build


14/20

Requirements Recommendations

Design for AM (DfAM)

From MachiningFrom Casting

Industry Sectors

Conformal CoolFins + Complex curvesOrganic shapesDesigns from Non. Mechanical CAD

Process-Orientation-Supports

Custom designsSize & Frequence

-Thick section reductions

Process-Orientation-Supports

Custom designsSize & Frequence-Thick section reductions


15/20

MTT S l N


16/20

MTT Sample No.

Minimum Requirement From Machining

Minimum Requirement From Casting

Industrial Example Mould tool

Industrial Example Aerodynamic

Industrial Example Medical

Industrial Example Dental

Industrial Example Automotive

Design Features Threads Internal/External

Process validation Process evaluation thick section - Stress assupport

Process validation Custom Supports


17/20

Design Rules for machining Think about the stock size that will be used.

Think about the sequence that the operations will be carried out

What fixtures will be required for m/cing in different orientations. Make sure as may operations are

done in a single setup as possible. Amount of tools, size, material removal and access. Milled pockets = rounded corners

Surface finish

Accuracy

Design Rules for casting Flow and cooling of molten metal.

Gating

Wall thickness / thick section (Stress) shrinkage

Surface finish Fill marks, weld lines, voids

Accuracy Shrinkage allowance

Being able to remove part from tooling (non-investment casting)

Tooling design & side action

Draft angle

Design Rules for SLM Think about orientation orientate for given priority* and identified critical features

Think about surface finish and critical dimensions / geometry

Think about thick sections remove as much as possible while still achieving part strength

Feature spacing and minimum feature size

Removing perpendicular faces. Make less than 90 degrees

*Extends EOS part property management concept in to design requirements5 Part property profiles (PPP)Top speed/Speed/Balance/Performance/Top Qualityrelated to layer thickness


18/20

Support performance & SLM specific custom styles


19/20

http://www.protomold.co.uk/ProtoQuote.aspx
http://www.protomold.co.uk/ProtoQuote.aspxhttp://www.protomold.co.uk/ProtoQuote.aspx


20/20

BADLarge material sections

Over hangs Will need to be orientated or supports added to buildUnsupported holes.Perpendicular surfaces. These influence possible build orientations,

Anything less than 90 is GOODPointy tapered things are GOOD

Geometry detail (holes, cut outs) inline with axis are GOOD

Need to think about;Material allowanceBuild orientationSurface quality.

Down-facing surfaces - RoughnessSide facing surfaces - Stair steppingSupport witness

Holes are better position parallel with build direction.

Documents

Marketing Flow Chart 270611