Design for Additive Manufacturing: Towards End-Part Production
I.D. # WB1705 Duration 10 Hours
Additive manufacturing (AM), withs origins in the 1980s, has only more recently emerged as a manufacturing process of choice for functional part production, adding to the suite of choices a designer has available when designing a part for manufacturing. Like other traditional processes like casting and machining, AM has its set of constraints. An added layer of complexity comes from the fact that there are several different AM processes, and some of the design constraints are process-specific. On the other hand, AM offers a range of opportunities in design freedom and mass customization as well as in cost and lead time reduction in some cases. Today, it is essential for designers to embrace AM as a possible manufacturing method to ensure their products are competitive and also to unlock the design innovation that AM enables.



The goal of this 10-hour course is to give designers the information needed to start designing for AM at all levels ┐ identifying and justifying use of AM technology for a particular part, selecting the right process and material for the application and ensuring it is designed with the advantages and considerations of AM in mind. The course is not intended to serve as a software-training class or as a deep dive into any specific AM process, but rather to draw connections between design and AM from a designer┐s perspective.



Learning Objectives
By participating in this web seminar, you will be able to:


  • List the different polymer and metal AM process technologies and materials and identify which of these are being used for functional part production

  • Select the optimum AM material and process for a particular application

  • Predict how design decisions impact manufacturability for the selected AM process and apply design rules and guidelines to your design process

  • Quantify the expected properties of the AM parts you are designing

  • Discover how topology optimization, cellular structures and other disruptive design techniques can be leveraged with AM and associated software tools

  • Identify the different drivers for adopting AM for a particular part, with regard to cost, lead time, supply chain and performance risks

  • Relate to the challenges and ongoing research efforts to be able to move forward with AM implementation in the presence of rapid change in the field

  • Develop a comprehensive strategy to bring AM for functional part production into your organization that addresses both the benefits and impacts

Who Should Attend
This training is relevant to and needed by designers that work in aerospace and automotive companies and are chartered with either designing next generation solutions, or even with designing for cost, replacement parts or tooling used in the manufacturing process. Designers that can use existing design tools but need to learn enough about AM so they can use these tools to design parts suitable for these manufacturing processes will especially benefit from this course.


Seminar Content
Session 1: Additive Manufacturing Process
  • Introduction to AM

  • Polymer AM

    • Fused Deposition Modeling (FDM)

    • Selective Laser Sintering (SLS)

    • Other processes and trends

    • Functional parts case studies

  • Metal AM

    • Powder Bed Fusion (PBF): laser and electron beam

    • Directed Energy Deposition (DED)

    • Other processes and trends

    • Functional parts case studies

  • Material Options and Selection

  • Key Process Concepts

    • Build sizes

    • Part orientation

    • Support management

    • Post processing

  • Considerations

    • Dimensional accuracy and tolerances

    • Surface roughness

    • Physical properties

    • Mesostructure

    • Mechanical properties



Session 2: Introduction to Design for AM
  • The Need for New Design Thinking with AM

  • Four Levels of AM Design

    • Prototypes and tooling

    • Direct part replacement

    • Part consolidation

    • Design for AM optimized

  • Introduction to Software Tools for AM

    • Solid modeling (CAD)

    • Topology optimization

    • Lattice materials design
    • Build preparation

    • Process simulation

  • Support Fundamentals

    • Purpose of supports

    • Process dependence

    • Self-supporting design concepts

    • The importance of orientation

  • Build Preparation SW Demos

    • Demo with Insight (FDM)

    • Demo with Magics (Metal)


Session 3: Topology Optimization
  • Motivation: The Case for Sustainable Design

  • Case Studies with AM

  • Introduction to Optimization Concepts

  • Material Models

  • Demo with ANSYS

    • Problem setup

    • Optimization

    • Smoothing

    • Validation

  • Manufacturability



Session 4: Lattice Materials Design
  • Biometric Underpinnings

  • Classification of Cellular Materials

    • Volume/space-filling

    • Surface

  • Functions and Performance Gains

    • Structural

    • Transport

  • Case Studies with AM

  • Modeling Approaches

  • Demo with nTopology

  • Manufacturability


Session 5: Implementing AM - A Practical Guide for Designers
  • Part Selection for AM

    • Purdue scorecard for part evaluation for AM

    • Cost considerations

  • Challenges and Open Questions

    • Environment, health and safety

    • Process, supplier, equipment selection

    • Material properties and modeling

    • Process variation: repeatability, reproducibility and tool-to-tool matching

    • Design software choices

    • Data handling & traceability

    • Standards

  • Successful AM Adoption Transition Strategies

    • Polymer to metal

    • Prototype to end-use part

    • Outsourcing to in-house

  • Resources

Instructor(s): Dhruv Bate
Dhruv BateDr. Dhruv Bhate is a Senior Technologist at Phoenix Analysis & Design Technologies, Inc. (PADT) where he leads R&D efforts in Additive Manufacturing (3D Printing), with a focus on high performance polymers, metals and biomaterials. Prior to joining PADT in 2015, Dhruv spent seven years at Intel Corporation developing several laser-based manufacturing processes, taking them from early-stage research to High-Volume-Manufacturing. He also spent a year as a manufacturing engineer in the automotive industry at Tata Motors.



Dhruv has two patents, nine peer-reviewed journal publications, seven peer-reviewed symposium papers and over 30 conference presentations to his name. He is also the co-founder and co-chair of the Arizona Additive Manufacturing Committee, a group of over 40 entities in Arizona that use AM technologies. Dhruv has a Ph.D. in Mechanical Engineering from Purdue University where he developed constitutive and failure models for the prediction of fatigue fracture in ductile metal alloys. Prior to this, he obtained his M.S. from the University of Colorado at Boulder where he studied adhesion in MEMS (Micro Electro Mechanical Systems) structures.



*Global toll-free telephone numbers are provided for many countries outside the U.S., but are limited to those on the WebEx call-in toll-free number list. Check here to see if your country has a global call-in toll free telephone number for this web seminar. If your country is not listed, you may still connect using the US/Canada Call-in toll number or Voice over Internet Protocol (VoIP).



Although WebEx Training Manager will automatically launch when you join the web seminar, you or your system administrator
are encouraged to download the plug-in in advance to help ensure successful setup. Click here, then follow the onscreen instructions.


NOTE: The course presentation will be recorded and made available for 30 days to those who register by the deadline.


Fees: $720 SAE Members*: $576 - $648
* The appropriate SAE Member discount will be applied through the Registration process.  Discounts vary  according to level of membership: Elite Member 20%; Premium Member 15%; Classic Member 10%
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