Efficient design iteration is key to staying ahead.
3D printing has revolutionised the way we approach prototyping and production, allowing for rapid design changes and quick feedback loops.
Software development has also allowed for a seamless and simple design process. Yet, that doesn’t mean there aren’t still more ways to speed up the design and development process when taking advantage of additive manufacturing.
So, here are some actionable tips to help you accelerate your design iterations for 3D printing enabling you to bring high-quality parts and prototypes to the market faster than ever before!
The Best Tips For A Faster Iterative Design Process For 3D Printing
Optimise Your Design Workflow
Optimising your workflow is a great way of speeding up the iterative design process. Here’s just a few ways of optimising your design process without sacrificing quality:
Streamline CAD Modeling
Use Parametric Design – Create parametric models that allow for quick adjustments of key dimensions without redrawing the entire model. This approach saves time and reduces errors during the iterative process.
Leverage Design Templates – Develop templates for recurring design elements and assemblies. Reusing these templates can significantly speed up the design process and provide your entire development team instant access to commonly used components and elements.
Integrate Design for Additive Manufacturing
Minimise Supports – Design parts to minimise the need for support structures. This can reduce printing time and post-processing. Or choose a 3D printing method that doesn’t require support structures like Selective Laser Sintering (SLS), for example.
Consider Orientation – Optimise part orientation in the build space to improve print speed and surface quality while reducing the need for supports. This is something that Prototal UK does for all of our 3D printing. It ensures print success and allows us to maximise the space on the print bed.
Utilise Rapid Prototyping Techniques
During the prototyping stage, an iterative approach is a great way of getting user feedback quickly and perfecting a product before it goes to market. However, this iterative development process can cause delays during user research, usability testing and functional testing. While we can’t help with the human element, we can help speed up the design and printing process:
Print Smaller, Representative Models
Scale Down – For initial design validation, print smaller, scaled-down versions of larger parts. This approach saves time and material while allowing you to test key design features. Plus, it also allows for user testing to some degree, and ensures that continual improvement can easily, and quickly, be made.
Print Critical Sections – Rather than printing smaller prototypes, print critical features like hinges and other mechanisms instead. Focusing on printing the critical sections of your design ensures that any features requiring immediate testing and validation can be tested by the project team without slowing down the iterative cycle with large, complex parts.
Layer Height and Infill Adjustments
Increase Layer Height – For early iterations, use higher layer heights to speed up print times. As you refine the design, decrease the layer height for better resolution.
Reduce Infill Density – Lower the infill density for non-functional prototypes to save time. Use higher infill for final prototypes to test strength and functionality.
Implement Agile Development Practices
Now, it isn’t just the computer side of the design process that you can speed up. The human element of the product development process can also be sped up. If previous iterations of your products have been slow to market, here’s a couple of ways to speed up the humans involved:
Short Iteration Cycles
Adopt Agile Methodologies – Implement agile practices such as sprints and regular stand-ups to keep the team focused and aligned on iteration goals. In project management sprints and stand-ups are key to continual testing and improvements. They ensure a small team can focus on the project and push forward to get to the end result as efficiently as possible.
Set Clear Milestones – Define specific milestones for each iteration to ensure steady progress and timely feedback. Remember, the iterative process is designed to creep up on the perfect design, not to nail it on the first try. So encourage your team not to get bogged down in the nitty gritty at each stage and focus on the milestones set.
Cross-Functional Collaboration
Enhance Communication – Foster open communication between design, engineering, and manufacturing teams. Regularly review iteration results and incorporate feedback swiftly.
Use Collaboration Tools – Use digital collaboration tools like Slack, Zoom or Teams, to share designs, feedback, and updates in real-time.
Use Simulation and Analysis Tools
An excellent way of speeding up the design process is to test the design as you go. With human-computer interfaces and user interface design software better than ever, you can now conduct virtual testing to ensure your designs are as close to perfect as possible before they are printed.
Virtual Testing
Finite Element Analysis (FEA) – Perform FEA on your CAD models to predict and address potential structural issues before printing.
Computational Fluid Dynamics (CFD) – Use CFD to optimise designs involving fluid dynamics, reducing the need for multiple physical prototypes.
Print Simulation Software
Predict Print Outcomes – Use print simulation software to identify potential issues such as warping or support requirements. This helps in making necessary design adjustments before the actual print, saving time on failed iterations. Once we receive your CAD model, all kinks should be worked out, and you’ll receive the precise parts you need for your product.
Outsource to Specialised 3D Printing Services
This is where we come in. We have the most advanced 3D printing technology in the UK. We can print in a host of different materials on some of the best 3D printers ever made. So, whether you need heat-resistant parts, flexible parts, or parts as strong as metal, we’re here to help!
Partner With The Experts At Prototal
Engineers can streamline the iteration process, reduce time-to-market and maintain high standards by accelerating design iterations. However, accelerating design iterations with 3D printing requires a strategic approach that encompasses optimised design workflows, appropriate technology selection, rapid prototyping techniques, agile development practices, and sometimes the use of advanced simulation tools.
Of course, if you need help from expert additive manufacturing engineers, then get in touch with Prototal UK today! We can help iron out your designs and print high-precision parts with technologically advanced materials to give you the competitive edge.