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Generative Piston Head
Generative Design, Prototyping 4140
Prototype piston head for a reciprocating engine, optimized with generative design. Typically CNC machined from aluminum alloy, pistons can be time-consuming and difficult to rapidly prototype and test.
It often takes months or even years to move from design to production. With the Studio System, various piston designs can be easily prototyped and tested—speeding up product development timelines, reducing time to market, and introducing new opportunities for optimization, including generative design—all while avoiding CNC backlog and lead times.
- Size (mm): 105 x 105 x 54
- Cost to print ($): 271.00
- Cost to machine ($): 568.13
- Savings vs. machining: 52.30%
Bound Metal Deposition™
This bracket holds a sensor in place on an industrial machine and leverages generative design to reduce part weight and material usage.
Only 100 brackets were needed for the initial pilot run of an industrial machine. The Shop System is an excellent manufacturing fit as it does not require tooling. Moreover, it allows production to kick off as soon as the design is complete. In other words, it significantly reduces manufacturing lead time and part cost.
Printing these parts on the Shop System also opens up a unique opportunity to easily apply generative design without the same geometric limitations met in traditional manufacturing. For this part, the team used Live Parts™ to optimize the geometry for the specific loading scenarios involved in the application as well as the build requirements of binder jetting.
- Size (mm): 68 x 43 x 33
- Cost per part ($): 36.51
- Parts per build: 30
- Weekly throughput: 271
- Binder Jetting
Generative Design, Live Parts™
This part attaches wheels to a skateboard deck and has been optimized using generative design tools.
Generative design and 3D printing allow the fabrication of innovative designs impossible with casting (the traditional production method for skateboard trucks).
Studio System 2 can print parts with complex geometries. With the help of generative design, trucks are more aesthetically pleasing, stronger, and lighter.
- Size (mm): 201 x 76 x 52
- Cost to print ($): 161.00
- Cost to DMLS ($): 1163.00
- Cost reduction: 86.00%
- Bound Metal Deposition (BMD)