Event 

Design For Additive Manufacturing 

by Wohlers Associates, Inc. 
on 5-Dec-2018 
at Melbourne, Australia 
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Delivered by: Wohlers Associates and RMIT Centre for
Additive Manufacturing
Location: Advanced Manufacturing Precinct
RMIT University, 58 Cardigan St, Carlton
Cost: $ 4,000


You are invited to attend a special three-day course on design for additive manufacturing (DfAM). Topics covered in the training include the consolidation of many parts into one and methods to reduce material and weight, such as topology optimization and lattice/mesh structures. It includes best practices and a wealth of DfAM guidelines. Participants will gain valuable hands-on experience by designing real parts and building them on industrial AM equipment.

Benefits of DfAM
The images show a hydraulic manifold for Atlas Copco mining equipment. The top version is a conventionally machined manifold with 12 nozzles that must be installed. The bottom version was redesigned for and produced by additive manufacturing. The AM version reduced weight by 91% and consolidated 13 parts into one, resulting in lower assembly cost, less weight and scrap, and the elimination of potential leakage points. Learn how to design these and many other types of parts in this special DfAM course.

You will...
• Become familiar with DfAM guidelines and best practices
• Design, redesign, and optimize products
• Use your favorite design software (if you are a CAD user)
• Gain experience with best-in-class DfAM software such as Inspire from solidThinking and the lattice-structure capabilities in Magics from Materialise

Who should attend...
The DfAM course is targeted at designers, engineers, and managers wanting to learn how to design parts that fully benefit from additive manufacturing. It is ideal for those involved in aerospace, medical, motorsports, energy/power, industrial machinery, automotive, and consumer products. 

Three-Day DfAM Course Outline
Date Topic Details
Day 1
8:30-8:45 Introduction Introduction to the course and attendees.
8:45-9:30 The state of the AM industry
Recent AM growth trends and developments around the world.
9:30-10:00 Intro to design for AM
Benefits of AM in the context of DfAM, how AM is being applied, and how certain parts can be designed for AM.
10:00-10:15 Break
10:15-11:00 Intro to design for AM (continued)
Benefits of AM in the context of DfAM, how AM is being applied, and how certain parts can be designed for AM.
11:00-12:00 AM process: from CAD to part
Examining the complete AM process chain, from CAD part creation, to part production. Attendees will gain an understanding of the entire process chain and how it helps them to design better AM parts, file formats, and working with STL manipulation software. Opinions and commentary on the major AM processes, materials, companies, and products.
12:00-12:30 Lunch
12:30-13:30 AM design optimization exercise
Thought processes behind DfAM. In this exercise, we will design a hydraulic manifold while considering print orientation and support material.
13:30-14:15 Economics of AM When does it make sense, or not make sense, to use AM for production quantities? What determines AM costs and can we design to minimize cost?
14:15-14:30 Break
14:30-16:00 Design for mass customization exercise
Hands-on exercise to design a custom product using a combination of CAD, 3D scanning, and STL editing software. This exercise introduces attendees to the idea of working with multiple software tools and technologies to produce parts optimized for AM.
Day 2
8:30-9:30 AM process: from CAD to part (continued)
Opinions and commentary on other popular AM processes, materials, companies, and products.
9:30-10:00 Designing for metal AM
Specific issues and guidelines around designing for metal AM, including anisotropy, process constraints, general guidelines related to wall thicknesses, hole sizes,  tolerances, angles, etc. Close look at metal AM post-processing and material properties.
10:00-10:15 Break
10:15-11:00 Designing for metal AM (continued)
Specific issues and guidelines around designing for metal AM, including anisotropy, process constraints, general guidelines related to wall thicknesses, hole sizes,  tolerances, angles, etc. Close look at metal AM post-processing and material properties.
11:00-12:00 Lattice structure exercise
A solid part is transformed into a shell filled with a lattice structure.
12:00-12:30 Lunch
12:30-13:30 Design to reduce residual stress
Redesign of a metal AM part in order to minimize the potential residual stress that would cause distortion
13:30-14:15 Designing for polymer AM processes
Specific issues and design guidelines surrounding polymer AM (material extrusion, LS, SL, etc.), including post-processing.
14:15-14:30 Break
14:30-16:00 Topology optimization
Designing topology-optimized parts for AM, and creating light-weight parts using software such as Inspire from solidThinking. Workflow of topology optimization, setting up multiple load-cases and using the generated ideas to produce a final design.
Day 3
8:30-9:15 Tooling applications of AM
AM beyond direct part production: Tools for injection molding, sheet-metal forming, cutting and drilling, extrusion, jigs, and fixtures, etc. Adding fixtures to parts to ease mounting on CNC machines for more efficient post-processing.
9:15-10:00 Part consolidation exercise
Implications of part consolidation for AM. Hands-on exercises in part consolidation.
10:00-10:15 Break
10:15-12:00 Putting it all together
Hands-on exercise to design a product that can be printed in metal with minimal support material and post-processing. The exercise applies what has been learned over the past three days.
12:00-12:30 Lunch
12:30-13:30 Expert panel session DfAM and AM experts offer opinions and answers questions from participants.
13:30-13:45 Break
13:45-14:30 AM in the future Looking at where AM and design software tools are headed in the future and the implications they will have on DfAM.
14:30 Conclusion

 



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