Inspiration to 3D Design

Abstract

A strong attraction of solid freeform fabrication is the removal of design constraints imposed by commercial metal shapes and conventional processes; opening a whole new world of design possibilities. Commercial metal shapes associated with sheet metal, tubing, angle iron, pipes and plates will not be going away anytime soon, but add the possibility of forming flowing organic surface shapes, complex passageways, and unique internal or external structures, and we can begin to rethink what is possible when working with metal. The same thinking can release us from shape constraints imposed by creating features using drilling, shearing, bending, milling and casting or pressing into molds. This chapter will describe the AM design process and compare it side by side with the design process for conventional metal processing. We will include a few examples of how one method is better than the other and which is right for you. We will discuss the advantages and disadvantages of selecting one material over another. In addition, we will highlight a few examples of hybrid applications, combining the best of 3D printing, conventional and subtractive processing and how 3D metal printing can define a new design space for thinking outside the box. This chapter will build upon the existing body of metal working design knowledge, complement it, transform it and take it to levels not possible in years past.