Methodology for 3D-Printed Part Design: Difference between revisions

What is 3-D printing?

1) Is there an existing demand for the part or product?

  If No, then determine why the part should be created.
  If yes, 
    What is the desirability? 

2) Is there an existing offering/part made by traditional manufacturing processes?

  If No, then determine why there is not an existing offering.
  If Yes, 
     What are the benefits of 3D printing the part? (e.g. geometry complexity, customization, density, rapid prototyping, reduce lead times, or unique material)

3) Is it feasible to 3D print part?

  Is the the volume of part less than the build envelope? 
  Maximum temperature range for part less than maximum temperature for printing material?

4) Determine and quantify necessary mechanical properties, standards, and loads for part.

  Determine applicable mechanical properties (e.g. Tensile Strength, Compression Strength, Flexural Strength, Impact Strength, Fatigue Limit, Wear Resistance, and Stiffness). 
  Reference industry standards for the part (e.g. ASTM International, ANSI, or ASME).

5) Prioritize necessary mechanical properties, standards, and loads for part.

  Based on requirements for part, prioritize Tensile Strength, Compression Strength, Flexural Strength, Impact Strength, Fatigue Limit, Wear Resistance, and Stiffness.
  Use prioritized list of mechanical properties to influence design considerations and FEA simulation.

6) Model existing part or prototype.

  Use Comparison of CAD Modeling  to determine best CAD Modeling software.
  OpenSCAD, FeeCAD, and Blender are the most commonly used Open source engineering software packages.

  Save an IGES file for Finite Element Analysis.
  Save a STL file for the slicing software.

7) Conduct Finite Element Analysis (FEA).

  Select from List of FEA Software Packages
  Review basics for Finite element analysis: MOST
  ANSYS and Abaqus are two commonly used FEA software packages.

  Insert Young's Modulus and Poisson's Ratio for material used.

8) Determine if part should be 3D printed based on (FEA).

  Does the part fail as anticipated?
  Does the upper-limit of failure meet the required mechanical properties, standards, and loads?
  Should the part be redesigned before printing?

9) Select the most appropriate 3D printing material.

  PLA, Nylon, and Polycarbonate are recommended. 
  Mechanical properties of components printed with PLA and ABS.
(Make table with parameters and references for PLA, Nylon, Polycarbonate).

10) Import CAD file into slicing software.

  Cura is the most commonly used slicing software.     
  slic3r is an alternative.  Useful documentation for getting started with Slic3r. 
  RepRap printing protocol: MOST contains information on preparing your file for printing.

11) Determine optimal printing build parameters in slicing software with regard to necessary properties, standards and loads.

(e.g. orientation, fill density, fill pattern, layer thickness, bead width, deposition temperature, deposition speed raster angle, etc.)

    How Does Build Orientation Affect a 3D Printed Part?
    Cura - Fill Density 
   
    Cura User Manual contains information on settings for layer height, shell thickness, enable retraction, bottom/top thickness, fill density, print spreed, print temperature, support type, platform adhesion type, filament diameter, and filament flow].
    Silc3r Print Settings contains information on settings for Layer Height, Perimeters, Fill Density, Fill Pattern, Support Material, Speed, Brim, Sequential Printing, Filament Settings, & Printer Settings

12) Export G-Code from slicing software and import G-Code file into 3D printing software.

   G-Code is the file type (.gcode) needed to print.

13) Select printing software.

   Repetier-Host and Pronterface are recommended.

   Repetier-Host Documentation
   Pronterface Basics
   

14) Ensure printer is calibrated.

   Calibration will depend on the type of 3D printer used. 
   Calibration Tutorial
   MOST Delta Auto Bed Leveling

15) Print part.

   RepRap printing protocol: MOST
   3D_Printing_Basics:MOST
   MOST_Reprap_Printing_Lessons
   Tips for Designing 3D Printed Parts

16) Test printed part to failure.

   Determine appropriate failure analysis method (e.g. Tensile, compression test, Torsion Test, or Rockwell Hardness.

(Describe testing process. Describe basic tensile test, compression test)

   Tensile test protocol: MOST

15) Does part fail as expected in FEA simulation?

   If No, reassess printing build parameters.
   If Yes, continue to next step.

16) Does part meet necessary mechanical properties, standards, and loads for part?

   If No, reassess CAD design and printing parameters.
   If Yes, compare 3D printed part to existing parts on cost, mechanical properties, etc.

17) Quantify and qualify why 3D-Printed product is better than existing offerings.

18) Cost Analysis

   (Compare costs of 3D-printed part to available offerings)

   The equation below can be used to determine the cost of printing a part:
      (Op) = (E)(Ce) + 1000(mf)(Cf) [1]
      
      Op: Operating costs for the RepRap-produced products
      E:  Energy use (kW-hr)
      Ce: Cost of filament (US$/kg)
      mf: mass consumed (g)

19) Continue iterative design process to optimize part for end user.

See also

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External links

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References

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