Browse Learn WB1705

Design for Additive Manufacturing: Towards End-Part Production WB1705

Additive manufacturing (AM), with 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.

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
Registration Information
Registration for this live web seminar is available on a per-person basis, similar to purchasing a seat in a classroom. Participants attend an online session from work or home; anywhere with a PC with internet access and a telephone. The fee includes one connection to the conference calls (toll free telephone number provided for U.S. and select countries*) and assigned personal ID number; one connection to SAE's online training center (via WebEx); and access to a secure course in the SAE Learning Center that contains the presentations, supplemental materials, and assignments.

Registrations will be accepted until 5:00 p.m. the day before the start of the web seminar, but early registration is encouraged to allow for pre-course set-up and instructions.

*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.

Multiple Seat Discount - Does your company have a group of employees who need this course? Register one individual at the appropriate member or list price, then register additional employees at half off the list price. Registration by phone with

If you cannot attend, you may register a substitute in your place or transfer your registration to a future offering. A full refund is issued if you notify SAE at least 14 days prior to web seminar start date. If canceled less than 14 days prior, the full fee is charged. For $50, you may process a one-time transfer to a future offering within one year of canceled web seminar. Canceling may reduce group discounts. To cancel, transfer or send a substitute, call SAE Customer Service at 1-877-606-7323 (US & Canada only) or 1-724-776-4970.

Dhruv Bhate

Dhruv Bate

Dhruv Bhate is an Associate Professor at the Arizona State University (ASU), The Polytechnic School, where he conducts research in the design and mechanics of Additive Manufacturing (AM) structures and materials, and teaches courses in AM processes, design and materials at the undergraduate and graduate level. Prior to joining ASU, Dhruv spent two years at PADT, Inc, a small business in Tempe, AZ, where he led the company's R&D efforts in Additive Manufacturing. Prior to joining PADT, he 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 in the automotive industry, working for India's largest car manufacturer, Tata Motors.

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 the phenomenon of adhesion in MEMS (Micro Electro Mechanical Systems) structures.

Dhruv's passion lies in combining theory, experimental methods and simulation to answer challenging research questions in new and effective ways, seeking inspiration from multiple disciplines.

Fees: $720.00
SAE Members: $576.00 - $648.00

1.0 CEU
You must complete all course contact hours and successfully pass the learning assessment to obtain CEUs.

To register, click the Register button above or contact SAE Customer Service 1-877-606-7323 (724-776-4970 outside the U.S. and Canada) or at

Duration: 10 Hours
June 3-12, 2019 (11:30 a.m. - 1:30 a.m.) - Live Online
September 9-18, 2019 (11:30 a.m. - 1:30 a.m.) - Live Online