Q: What is design-for-additive-manufacturing (DfAM)?

DfAM is the practice of redesigning parts to exploit AM's geometric freedom (lattice structures, internal channels, part consolidation) while respecting its constraints (overhang angles, support access, residual stress, anisotropy). It is the single biggest lever for AM business case ROI.

Question 1

How do I choose between LPBF, DED, and binder jetting for a metal part?

Accepted Answer

LPBF is the default for small-to-medium complex parts with tight tolerances (under ~400mm build envelope). DED is suited to large, less complex parts and repair/cladding workflows. Binder jetting wins on throughput and unit cost for series production of small parts with relaxed surface requirements.

Question 2

What standards govern AM part qualification?

Accepted Answer

Core standards include ASTM F42 / ISO TC 261 joint publications (terminology, process control), ASTM F3318 for aerospace LPBF, ASME BPVC for pressure vessels, and SAE AMS-AM specifications. Sector-specific overlays apply: AS9100 for aerospace, ISO 13485 / FDA for medical, IATF 16949 for automotive.

Question 3

What surface finish can I expect from production AM processes?

Accepted Answer

As-built Ra values typically land at 4–15 µm for LPBF metals, 8–25 µm for SLS polymers, and 15–40 µm for DED. Post-processing (machining, abrasive flow, electropolish, vibratory) reaches Ra <1 µm but adds significant cycle time and cost — design with the as-built surface in mind where possible.

Question 4

What is design-for-additive-manufacturing (DfAM)?

Accepted Answer

DfAM is the practice of redesigning parts to exploit AM's geometric freedom (lattice structures, internal channels, part consolidation) while respecting its constraints (overhang angles, support access, residual stress, anisotropy). It is the single biggest lever for AM business case ROI.

Process selection and qualification

What material type do you primarily work with?