[Data: Alther Inspire Phase Optimization SW]

- Definition of DfAM.

Design for Manufacturing (DFM) is a design concept that maximizes the advantages of 3D printing with Design for Additive Manufacturing (DfAM).

- DfAM necessity

Previously, cutting processing made by cutting iron was severely restricted in shape and complicated drawings could not be produced. There are various cutting methods such as 4-axis and 5-axis, but there is a limit to manufacturing complex and precise parts due to the nature of cutting tools that cut iron while rotating at high speed. Stacked processing is a concept that contrasts with cutting processing and creates a shape by stacking materials, so if you have a supporter, there is no limitation in shape, so you don't have to think about what is impossible to process when designing.

The main purpose of 3D printing is optimized for prototype production and customized multi-species production, which will soon be necessary to create products that cannot be manufactured in special fields such as medical, aviation, automobile, mold, and materials, and will utilize DfAM technology.

[Data DfAM Example - GE Fuel Nozzle]

- Technology and field of DfAM application

Metal is the material that best fits the DfAM technology required to maximize the advantages of 3D printing. Complex shapes can also be produced with supporters, so for metal materials with high proportions, unnecessary parts can be removed (phase-optimized) or replaced with grids to reduce weight. Compared to other materials, it is very lightweight and is actively used for metal 3D printing.

DfAM application technologies include lattice structure and topology optimization, single parts made of multiple parts, and porous structural design specialized for medical use, and can be used interchangeably depending on purpose and purpose. DfAM technology has the advantage of being able to reduce weight and unify parts while satisfying the product's performance goals (strength, dimensions, performance) through structural analysis. In Korea, there are various tools such as Altherr, Materialize, and Auto Desk, but the goals they pursue are all the same.  

[Data - Structural analysis of Materialise DfAM]

> Lattice Structure

It is possible to save and reduce materials at the same time by replacing unnecessary parts with grid structure within a scope in which a shape is not deformed, and this technology is used in various fields, such as industrial, medical, etc. depending on the shape and size of grid structure. Unlike phase optimization, it is effective when the shape must be maintained and can replace the most important supporter role in metal 3D printing..

> Topology Optimization

It is a concept that optimizes the structure of objects and optimizes material distribution within a given design space while satisfying the performance goals of the product, and is a technology that enables material saving, part unification, and weight reduction at the same time. Because weight reduction is the main purpose, it is optimized for purpose and purpose rather than maintaining the existing shape.

[Photo sample - Alther Inspire Topology Optimization Case]

- DfAM case – heat exchanger field

[Figure] Heat exchanger with DfAM technology. Example - SLM, 3D Systems

        Mold core (Applied DfAM)                  Conformal Cooling Channel Applied seat.                               Final production.

[Figure] DfAM technology applied: mold cycle time 109s -> 62s (45% reduction in cycle time)

Prove positive effects on cost reduction, productivity, and quality improvement by reducing the existing injection cycle.

Partner Lab is currently manufactured in Korea by combining metal AM technology with mold cores.