Re-designing a component or an assembly to incorporate additive manufacturing requires complete overhauling of the features for better and for worse in order to comply with the short-list of AM design requirements. This process will involve the original design engineers as well as a design engineer unfamiliar with the part’s manufacturing history or design history. New perspective with AM in mind opens design considerations.

Designing a part from scratch with the understanding of an AM machine’s printing process, supporting features and orientation, and physical properties and features that can be printed using DMLS will greatly reduce the frustration and barriers of outdated specifications and manufacturing requirements. The orientation of a printed part will determine the necessary external and internal support structure patterns and density. Bridging gaps, overhangs, angled walls, internal features should be used while determining a proper orientation method. Support structure and orientation will be a determining factor in whether a printed part will hold expected physical test properties.