Table 8 Results of applying the proposed DfAM strategies to case study 1

Support structures, cavities and overhangs

To reduce cost, material use, weight and production time, a hollow structure was considered, providing access to the support structures for their removal

Part size

Since the dimensions of the breast implant are smaller than the system workspace, no part size problems were envisaged

Thin sections

In order to reduce the production time and increase the structural strength of the part, a 0.5 mm layer thickness was selected. The wall thickness of the part was selected as 2 mm, i.e., four times the layer thickness

Geometrical features

The model did not have fillets, knife edges or small features

Part orientation

Part orientation was set with the minimum height matching the build orientation in order to reduce the production time

Path planning

A hollow structure was considered to reduce part cost, production time, material use, and part weight

Stability and post-processing

In order to ensure the stability of the part during its construction and to reduce the support structures, the largest and flat surface of the model was selected as the basis. Post-processing work was considered to remove the support structures, improve the surface finish and eliminate the staircase effect

Design with materials

ABS was selected as the part material because it will not be subjected to mechanical loads. PLA was selected as the support material because it can be removed by dipping the part into water at a temperature above 80 °C [92]

Part cost

A hollow structure was considered to reduce part cost, production time, material use, and part weight