3D Design in Manufacturing

Mechanical CAD (MCAD) software vendors are adapting to the demand for design processes that are more adaptable and conducive to teamwork and 3D design in manufacturing. This demand is encapsulated in what some call the three "A's" of modern design: agile development, augmented reality, and additive manufacturing.

Incorporating 3D design into these processes not only enhances the visual aspect of modeling but also significantly improves accuracy and efficiency, allowing for more complex and precise designs to be realized in a collaborative, digital environment.

Agile Development

Agile development is a software development approach that prioritizes incremental progress, continuous feedback, and team collaboration that is now being integrated into mechanical design. This integration involves segmenting extensive projects into smaller, more manageable components, enabling regular updates, and facilitating smooth cooperation throughout the design phase.

For decades, MCAD products have largely adhered to a one-user-one-part paradigm. However, vendors are now "tearing down walls" by introducing various in-software collaboration features. CAD software companies are devising strategies to match the collaborative versatility found in PTC Onshape, the sole native cloud-based MCAD design platform.

Augmented Reality

Virtual collaboration spaces, initially developed for the gaming industry, are now attracting attention in the manufacturing sector. Nvidia's Omniverse has emerged as a frontrunner, with its technology being adopted by a variety of companies. These virtual environments can be accessed through traditional flat screens or through a range of "reality" headsets, offering an immersive 3D experience.

MCAD tools are responsible for geometry, whereas simulation tools (CAE) are tasked with defining and testing physics. Software developers constantly enhance their products by exploring new ways to integrate CAD and CAE more closely. Many times, this results in design technology that favors AM. Such advancements encompass topology optimization, the generation of lattice structures, and the creation of printing supports to hold novel shapes in place until hardened. Additionally, the move towards early-stage simulation — applying simulation at the initial phases of the design process — further aids in optimizing designs for AM.

PTC’s Creo Topology Optimization Extension allows users to establish a defined set of objectives and constraints and the extension will automatically determine the best design. Image source: PTC.

Topology optimization enables designers and engineers to set specific design goals, constraints, and loading conditions for their 3D models. Utilizing these parameters, the software proposes the most efficient material layout within the designated design area, eliminating superfluous material without compromising the design's performance standards. Such a method is instrumental in developing designs that are both lightweight and material-efficient, proving particularly beneficial in sectors where minimizing weight and maximizing material use are paramount.

Additive Manufacturing

The first 3D printers on the market quickly became known in manufacturing as “rapid prototyping” machines. Today, they have become much more. 3D printing, now known as additive manufacturing (AM), is rapidly becoming accepted as the third primary method of industrial fabrication, along with formative and subtractive. For more about AM, read Cadalyst's series, "Additive Manufacturing 101."

One reason for the rapid growth of AM is that AM processes can sometimes accomplish what is otherwise impossible. For example, simulation software can confirm how oddly arranged channels improve cooling, yet such novel designs are either impossible to make with CNC or too expensive to make with formative methods. Enter AM, which can prove the design works. In fact, as technology continues to develop, a new genre of design exists — a subset of Design for Additive Manufacturing (DfAM) — just to create conformal cooling channels in injection molds. 

 
Using DfAM, a GE engineering team designed this lattice structure of a fuel nozzle which weighed 25% less than the original and 5X stronger. Image source: PTC.

AM is not the only innovation game in town. From the new hire in engineering to the CEO, everyone agrees product development and manufacturing needs to be more flexible and agile.

3D Design in Manufacturing

We stand at the forefront of a new era in manufacturing. The convergence of agile development, augmented reality, and additive manufacturing has gone from academic concepts to become a practical roadmap guiding unprecedented innovation and efficiency.

As MCAD software evolves to become more interconnected and user-friendly, it paves the way for a more collaborative and innovative approach to manufacturing. These advancements not only reflect the dynamic nature of the industry but also underscore the relentless pursuit of efficiency, precision, and sustainability.