Table 9 Results of applying the proposed DfAM strategies to case study 2

Support structures, cavities and overhangs

To reduce the use of support structures and avoid cavities, parts were orientated as shown in Figure 7. The pump casing was orientated with the holes axes matching the build direction

Part size

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

Thin sections

To reduce the production time a 0.5 mm layer thickness was selected

Geometrical features

The small holes of the pump casing 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 7

Path planning

Distortion, shrinkage & warping

Accuracy

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

Stability and post-processing

In order to ensure the stability of the parts during construction, the parts were orientated as shown in Figure 7. Post-processing was considered to remove the support structures of the gears, improve the surface finish and eliminate the staircase effect

Design with materials

The ABS was selected as the part material because the parts won’t be under mechanical loads. The PLA was selected as the support material

Part cost

The parts were orientated to reduce the use of support structures and material