White Paper: Manufacturing & Prototyping

Design Optimization Strategies: Transitioning from Traditional Manufacturing Technologies to HP Multi Jet Fusion Technology


The highest value for additive manufacturing is achieved when 3D printing is introduced into the very early stages of the product lifecycle. At these stages, designers can consider designs that are only possible through additive manufacturing, the combination of assemblies, and the optimization of the designs for the specific manufacturing process. The role that design plays in the process changes depending on where the product is in its development cycle.

In many cases, however, it is easier to start the adoption journey with an existing product. This paper presents several automatic design optimization methods that can help you take full advantage of additive manufacturing when moving production from traditional manufacturing methods to those that involve HP Multi Jet Fusion (MJF) technology for parts that have already been designed.

The re-design decision trees presented in this paper will help your teams filter through the possible parts that can be 3D-printed and assess the recommended re-design strategy for each part. The factors that affect that decision include how solid the part is, its size, the desired production volume, and mechanical requirements.

There are three re-design strategies detailed in this paper that can be used when a part has already been designed for another manufacturing method: hollowing, internal lattice structures, and topology optimization.

Hollowing is especially suited for solid parts that do not have high mechanical requirements so automatic re-design can be applied in minutes. Cost and weight of the part are highly reduced.

Lattice structures are especially suited for solid parts that require mechanical properties. Automatic re-design can be applied in minutes once the type of lattice needed for the specific part is chosen.

Topology optimization is especially suited for thin parts or parts that have complex load distributions. The re-design time investment is higher and requires more engineering hours. Optimized weight reductions are achieved given the computational nature of the process while maximizing mechanical properties of the part.

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