Design for 3D Printing: case study for a cold plastic deformation mould

Integration of additive manufacturing throughout a product’s lifecycle has proven over the years to bring substantial competitive advantages to companies worldwide. Complex geometries, quick iteration and lead-time reduction are universally seen as the biggest benefits of 3D printing. North American users also cite cost savings as a major benefit. More than half of the technologies’ applications are related to prototype manufacturing, especially due to high-cost savings in the development phase. Complex prototypes often require a cross reference when it comes to the design rules which need to be considered during the development stage. Thus, this study aims to analyze the various parameters when designing and manufacturing a complex prototype using material extrusion. Some of the main issues covered are related to analyzing the interference between components, adjusting the dimensions of the component elements according to the material contractions, the amount of used material and the total scrap and costs. In order to evaluate the abovementioned, a case study for a cold plastic deformation mould was chosen. The components were designed and assembled in a 3D software after which, each part was exported in *.STL and *.Gcode formats. Assembly tests were performed on the 3D printed components in order to adjust the dimensions. Project planning was used to propose an accurate time frame for the final complex prototype. Cost evaluation and material consumption were discussed in relation to functional, technological and economical restrictions. A final budget and general design rules were proposed for 3D printing of the complex functional prototype