Folks,
At EastBridge, our engineers rely on our 3D printers to produce models and early-stage prototypes for emerging new products. The ability to quickly spin out parts with an ever-growing range of resins and metals allows us to quickly iterate and develop proof of concept. Not having to commit to diecasting or injection molding tooling represents enormous savings in both cost and time.
While 3D printing is empowering as a preparatory step to industrializing a new product, it doesn’t eliminate the need to generate part designs that are suitable for volume production.
Parts that are ready for manufacturing often appear cored, or hollow, when compared to 3D printed prototype iterations. This is because, at the manufacturing scale, parts are optimized to use as little material as possible to minimize weight to save on cost, which can increase exponentially with each additional gram.
To this point, we’ve developed a checklist of factors to consider when transitioning from 3D printed parts to volume production:
- Design for Manufacturability (DfM):
While 3D printing allows for complex geometries, production processes often have limitations.
Consider factors like wall thickness, undercuts, support structures, and material properties to ensure the design is compatible with the chosen manufacturing method (injection molding, casting, etc.).
- Material Selection:
3D printing materials are diverse but might not offer the same mechanical properties, durability, or aesthetic finish as traditional production materials.
Choose materials that meet the functional requirements and production constraints of the final product.
- Tolerances & Surface Finish:
3D printing can have inherent layer lines and variability in tolerances.
Tighten tolerances and consider post-processing techniques (sanding, polishing, etc.) to achieve the desired surface finish for a production-ready look and feel.
- Assembly & Part Consolidation:
3D printing excels at creating complex, single-part assemblies.
For mass production, evaluate if redesigning for simpler assembly or part consolidation can reduce costs and improve manufacturability.
- Testing & Iteration:
3D printed prototypes are invaluable for testing form, fit, and function.
Iterate on the design based on feedback, ensuring the final product is optimized for both performance and production efficiency.
By carefully considering these five points, designers can leverage the advantages of 3D printing for prototyping and seamlessly transition to a production-ready design that meets both functional and manufacturing requirements.
Cheers,
Jack Daniels +1.617.285.2486