Table 10 Results of applying the proposed DfAM strategies to case study 3

Support structures, cavities and overhangs

To reduce the use of support structures and avoid cavities and overhangs, parts were orientated as shown in Figure 8. According to these part orientations, none support structures were needed

Part size

Since the dimensions of each part were smaller than the system workspace, part size problems were not envisaged and each part was fabricated separately

Thin sections

To reduce the production time and increase the structural strength of the part, a 0.5 mm layer thickness was selected

Geometrical features

Small holes of the cap-end heads were orientated vertically

Part orientation

To reduce the use of support structures, and to guarantee the stability of the parts during construction, parts were orientated as shown in Figure 8

Path planning

Distortion, shrinkage & warping

Accuracy

To increase the accuracy of the components and avoid distortion or warping, a closed and alternating filling pattern was used in all parts

Stability and post-processing

All parts were orientated with the largest flat area matching the build platform to ensure stability during fabrication, Figure 8. Post-processing work was considered to improve the surface finish and eliminate the staircase effect

Design with materials

The ABS was selected as the part material because it will not be under mechanical loads. The PLA was selected as the support material

Part cost

To reduce the use of support structures and material, the parts were orientated as shown in Figure 8