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FEATURE CAD/SOFTWARE


Still seen primarily as a prototyping


technology, additive manufacturing (AM) is getting a boost


from AI and machine


learning software that can help with AM decision making


3


D printing has been with us for more than 40 years, yet additive manufacturing (AM), which can deliver enormous value, is still greatly


underutilised. When properly implemented, it can reduce material waste and energy costs, improve part reliability, decrease lead times, reduce or eliminate the need to carry inventory, and optimise the production of legacy parts. However, transitioning to AM requires a change


in mindset plus the ability to quickly and easily identify which parts are best suited to the process. This is where AI and machine learning are now bridging the gap between traditional AM – where most of its value materialises in the form of functional prototypes – and more advanced additive manufacturing operations.


Unlocking the valUe of aM


with software scanning parts


The software’s algorithm and machine learning can scan thousands of parts at once by analysing CAD files. It evaluates five factors: materials, CAD geometry, costs, lead time and strength testing, to identify suitable parts for AM. The software can also make Design for Additive Manufacturing (DfAM) suggestions regarding part consolidation and weight reduction opportunities. “The software delivers a lot of detail. For


instance, it will tell you whether your costs can be reduced with an improved design or by selecting a different material,” explained Omer


Blaier, co-founder of Castor. “So, let’s say a manufacturer determines that a lower-cost material is more important than the strength. The platform would then recommend a material better suited for your design.” For Danfoss, there has always been a desire


to increase its AM processes, both for DfAM on its new products, as well as its existing product lines and legacy parts. “There are a lot of big companies out


there trying to get engineers to think about additive manufacturing when designing a new component,” added Blaier. “We come at it from the other side, trying to find opportunities within your current designs.”


aM for the Military


Few organisations, if any, have a larger library of part designs than the U.S. military, which is increasingly looking to AM as a potential solution to a number of challenges. For example, both the Air Force and Navy are in the process of creating an end-to-end digital manufacturing solution that slashes cycle times from weeks to hours, thus greatly decreasing project costs. “We are talking about millions, or even billions,


of parts in its arsenal. There was just no way the U.S. military could go through each one of those manually and figure out which components could


Companies that are looking to automate the


process of identifying which parts should be moved to additive manufacturing are increasingly relying on new industrial 3D printing software that can quickly determine AM feasibility. As an example, Danfoss, a leader in drives, HVAC and power management systems, utilises a platform that helps manufacturers unlock the benefits of industrial 3D printing by providing a technical and cost-saving analysis. The Castor3D software allows the company to focus on its end components and more specifically the costs associated with that. Commenting on this, Werner Stapela, head of


global additive design and manufacturing at Danfoss, said: “We have upwards of a million part numbers. It would be impossible for us to manually analyse each one to determine whether additive manufacturing would either add value or reduce costs.”


2 DESIGN SOLUTIONS SEPTEMBER 2023 8


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