Design for AM

Honeywell: Driving AM application and supply chain development in the aerospace industry

Over the past decade Honeywell has been a leader in accelerating the adoption of metal Additive Manufacturing in the aerospace industry. With dedicated facilities in five countries, the company is at the forefront of the development of new commercial aerospace applications and the supply chain needed to implement series production. Dr Dhruv Bhate, Associate Professor in the Polytechnic School at Arizona State University, visited Honeywell’s Phoenix facility on behalf of Metal AM magazine and met with Donald Godfrey, an Engineering Fellow at Honeywell and the person most credited with initiating and directing the company’s progress in the field of metal AM [First published in Metal AM Vol. 3 No. 3, Autumn 2017] ... Read more »

Design for Additive Manufacturing: Increasing part value through intelligent optimisation

Paying the right amount of attention to Design for Additive Manufacturing (DfAM) can make the difference between economic success and failure. When considering Additive Manufacturing for production applications, it is important to consider designing, or redesigning, parts that would otherwise be produced using conventional manufacturing. In this case study, Terry Wohlers and Professor Olaf Diegel, both of Wohlers Associates, reveal how industrial mining machine manufacturer Atlas Copco has used DfAM to increase the value of a hydraulic manifold [First published in Metal AM Vol. 3 No. 3, Autumn 2017] ... Read more »

Design for Additive Manufacturing: Transforming RF antennas through intelligent optimisation

Additive Manufacturing presents the opportunity to completely rethink a product’s design, transforming its functionality and reducing manufacturing complexity. With the right application and the right approach, the results really can live up to industry buzzwords such as ‘disruptive’ and ‘transformational’. In the following article, Optisys LLC reveals how, through intelligent design optimisation, the company has used Additive Manufacturing to develop the next generation of RF antenna systems for aerospace and defence [First published in Metal AM Vol. 3 No. 3, Autumn 2017] ... Read more »

Metal Additive Manufacturing gains ground in the tyre industry

The global tyre industry and its supply chain met in Hannover, Germany, from February 14-16 for the Tire Technology Expo 2017. This exhibition and accompanying technical conference was held at the Hannover Messe for the second time and attracted 280 exhibitors and close to 5000 international visitors. Dr Georg Schlieper visited the exhibition on behalf of Metal Additive Manufacturing magazine and reports on the growing use of Additive Manufacturing in the tyre industry [First published in Metal AM Vol. 3 No. 2, Summer 2017] ... Read more »

Distortion in metal Additive Manufacturing: Modelling and mitigation

There is a growing recognition that software can play a vital role in determining the success or failure of Additive Manufacturing within an organisation. As Autodesk’s Michael Gouge and Pan Michaleris explain, metal AM is about far more than having the right machine or specifying the right material. Dedicated AM software can today quickly and accurately simulate distortion in metal AM processes, significantly reducing build failure rates, minimising the associated economic impact and contributing to the enhancement of the technology’s reputation amongst end-users [First published in Metal AM Vol. 3 No. 1, Spring 2017] ... Read more »

The science behind a basic consumer product: Bottle openers by metal Additive Manufacturing

Bottle openers manufactured by metal Additive Manufacturing have become a popular promotional gift, with a variety of designs produced by AM technology suppliers. In the first of a new series of design oriented articles for Metal Additive Manufacturing magazine, Olaf Diegel and Terry Wohlers reveal how these products effectively demonstrate several key concepts that designers need to understand in the development of parts for production by metal AM [First published in Metal AM Vol. 3 No. 1, Spring 2017] ... Read more »

Accelerating AM component design workflow with new optimisation technology

Additive Manufacturing promises huge benefits for industry, but exploiting these in practice can prove difficult. For example, although truss-like component forms will often be found to be much more structurally efficient than traditional forms, identifying these has thus far been laborious and time-consuming. However, a new optimisation approach means that engineers can now directly identify optimised truss forms for AM components, saving time and effort. Prof. Matthew Gilbert of LimitState and the Advanced Additive Manufacturing (AdAM) Centre at the University of Sheffield outlines the technology and its application [First published in Metal AM Vol. 3 No. 1, Spring 2017] ... Read more »

Modelling the mechanical behaviour of additively manufactured cellular structures

One of the most promising aspects of Additive Manufacturing is the design freedom it enables. One manifestation of this design freedom lies in our ability to manufacture cellular structures such as lattices and honeycombs. Implementing cellular structures with AM, however, poses a range of design and manufacturing challenges. In this article Dr Dhruv Bhate, from Phoenix Analysis & Design Technologies, Inc. (PADT), focuses on a key area connecting design and manufacturing to final part implementation – the mechanical behaviour of these structures and the challenges and approaches to developing a reliable way to predict it [First published in Metal AM Vol. 2 No. 4, Winter 2016] ... Read more »

FIT AG: Laying the foundations for high-volume metal Additive Manufacturing

There is no doubt that the Additive Manufacturing of series components is quickly becoming a reality. From high-profile applications in the aerospace industry to performance components for the automotive sector, there are now numerous examples of the successful implementation of metal AM. However, the route that a company chooses in order to adopt AM technology could have a significant impact on a component’s development time and cost. As Nick Williams reports, Germany’s FIT AG sees opportunities in leveraging its expertise to supporting companies with the outsourcing of component development and production. To achieve this, the company has created a model AM factory that it plans to replicate worldwide [First published in Metal AM Vol. 2 No. 3, Autumn 2016] ... Read more »

Metal AM in the automotive industry: New vehicle structures, series components for the luxury market and beyond

The automotive industry has successfully embraced metal Additive Manufacturing as a prototyping technology for a number of years. As the technology advances, however, the possibilities for the use of metal AM for series component production are now starting to be explored. In the following review the challenges and opportunities for metal AM in the automotive industry are presented, including a radical concept to use AM parts as key structural elements in the next generation of automotive spaceframes [First published in Metal AM Vol. 2 No. 2, Summer 2016] ... Read more »

Download the latest issue of Metal AM magazine

Our latest issue is now available to view online or download in PDF format.

As well as an extensive AM industry news section, this 204-page issue includes articles and reports on:

  • Optimised thermal management in semiconductor fabrication using AI-enabled generative design and Additive Manufacturing
  • Forging a process for mass customisation via metal Additive Manufacturing
  • Bringing it all together: How Materialise is integrating manufacturing and software expertise to shape AM’s future
  • Pedal to the metal at the Digital Manufacturing Centre: Redefining what’s possible for AM in hypercars and beyond
  • The future is Additive Manufacturing – if we take a more holistic view of the design opportunities
  • Building a case for radical collaboration plus quality standards: The pathway to growing the AM industry
  • Distributed manufacturing: Old concept, new relevance, new technology?
  • Design for Additive Manufacturing: A workflow for a metal AM heat exchanger using nTopology (BJT)
  • Taking the holistic view:
    Defining the state-of-the-art in the evolving PBF-LB machine marketplace
  • > More information

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