Additive Layer and Design for Manufacture

Efficient manufacturing solutions which are based on the principles of Design for Manufacture (DFM).
Our team have many years of experience when using Design for Manufacture and Additive Layer Manufacturing which has been used within the design process as a material, a solution and an application.
We design a methodology which is based around process-structure-property-behaviour and we can support and help you to design and develop a new concept or optimise a current design.
Calculations are always carried out where required, through the software and rechecked with hand calculations.
Materials are selected through a performance and operational environment brief with the client, whilst considering budget, manufacturing and sustainability requirements.

This is the process of designing or engineering a product to facilitate the efficient and practical manufacturing process in order to reduce time, cost and complexity.
DFM will allow potential issues to be identified and resolved in the design phase which ultimately reduces cost and risk downstream. The design approach of a component will have an enormous effect on the cost of manufacture.
This links to a new key area involved with Design for Manufacture, known as Additive Manufacturing or Additive Layer Manufacturing.

DFM has typically meant that designers would tailor their designs to eliminate manufacturing difficulties and minimise costs.
Improvements in rapid prototyping (RP), or Additive Layer Manufacturing (ALM) technologies provide an opportunity to re-think DFM to take advantage of the unique capabilities of this technology.
Due to the advances of additive manufacture (ALM) technologies, it is now being commonly used as a final solution for small batch manufacture and not just for models or prototype evaluation.
This technology and process is now being used in multiple sectors including medical, aerospace and fabricated moulds to name but a few.

The unique capabilities of ALM technologies enable new opportunities for pushing design boundaries and customisation, very significant improvements in product performance, multi-functionality, and lower overall manufacturing costs.
Shape complexity: it is possible to build virtually any shape; lot sizes of one are practical; customised geometries are achieved readily; and shape optimisation is enabled.
Material complexity: material can be processed in one point, or one layer, at a time, enabling the manufacture of parts with complex material compositions and designed property gradients. It should be noted new materials are being developed almost on a weekly basis.