5 - Design principles

Abstract

Laser powder bed fusion technology is technically and economically mature and provides an opportunity for commercially significant engineering outcomes. These commercial outcomes are predicated on a robust understanding of the design tools and methodologies enabled by laser powder bed fusion (L-PBF). This chapter synthesizes commercial best-practice and emerging design opportunities to enable clear insight into optimal L-PBF design practices. Specific contributions are made for: digital design management; topological and parametric design optimization; generative design; material selection; and uncertainty quantification. Within these themes, important design tools are presented in further detail, including generative design methods that can enable L-PBF for high-value, low-volume design scenarios. Both commercial and industrial aspects of these design practices are demonstrated—in particular, the time-value of money is considered to highlight design opportunities for L-PBF to add value in time-critical design scenarios. These observations are presented with reference to both scholarly literature and commercial case studies of relevance.