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Comprehensive Design and 3D Modeling Services for Additive Manufacturing

Successful additive manufacturing begins with exceptional design. Our team of experienced designers and engineers specializes in creating 3D models optimized specifically for additive manufacturing processes, ensuring your projects achieve the perfect balance of functionality, aesthetics, and printability.

Our Design Services Spectrum

We offer a complete range of design services to support your additive manufacturing needs, regardless of your starting point:

Design for Additive Manufacturing (DfAM)

Our team specializes in Design for Additive Manufacturing (DfAM), a methodology that maximizes the benefits of 3D printing while minimizing its limitations:

• Support Optimization: Designing parts to minimize or eliminate the need for support structures, reducing post-processing time and improving surface finish.
• Orientation Planning: Determining the optimal print orientation to enhance strength, minimize supports, and improve surface quality.
• Wall Thickness Analysis: Ensuring appropriate wall thicknesses for different materials and technologies to prevent warping or breakage.
• Tolerance Engineering: Designing with appropriate tolerances for moving parts and assemblies, accounting for the specific characteristics of additive processes.
• Feature Optimization: Adapting features like holes, threads, and overhangs to print successfully without requiring extensive post-processing.

Reverse Engineering

Need to recreate an existing part or improve upon it? Our reverse engineering services can help:

• 3D Scanning: High-precision scanning of physical objects to create accurate digital models.
• Point Cloud Processing: Converting scan data into usable 3D models.
• Feature Recognition: Identifying and recreating critical features from scanned data.
• Design Enhancement: Improving upon original designs while maintaining critical dimensions and functionality.
• Documentation: Creating comprehensive technical documentation for reverse-engineered parts.

File Preparation and Optimization

We ensure your designs are perfectly prepared for the printing process:

• File Format Conversion: Converting between different CAD formats and ensuring compatibility with additive manufacturing systems.
• Mesh Repair: Fixing common issues like non-manifold edges, holes, and intersecting faces that can cause print failures.
• Resolution Optimization: Balancing file size and detail level for optimal printing results.
• Slicing Parameter Development: Creating custom slicing profiles for specific applications to achieve the best results.
• Print Simulation: Identifying potential issues before printing through advanced simulation tools.

Our Design Process

When you work with our design team, you can expect a structured, collaborative approach:

1. Initial Consultation: We begin by thoroughly understanding your requirements, objectives, constraints, and timeline.
2. Concept Development: Our designers create initial concepts based on your requirements, presenting options for your feedback.
3. Design Refinement: We refine the selected concept, incorporating your feedback and optimizing for additive manufacturing.
4. Technical Validation: Our engineers analyze the design for printability, structural integrity, and functionality.
5. Final Design Approval: You review and approve the final design before production begins.
6. Production Support: Our design team remains involved during the printing process to address any issues that may arise.

Software and Tools

Our design team utilizes industry-leading software to create exceptional designs:

• CAD Software: SolidWorks, Autodesk Fusion 360, Rhino, CATIA, and more
• Organic Modeling: ZBrush, Blender, 3ds Max
• Simulation Tools: ANSYS, Abaqus, Simscale
• Topology Optimization: nTopology, Altair Inspire
• Slicing Software: Simplify3D, Cura, PreForm, and proprietary solutions

Whether you're starting with a rough sketch, a detailed concept, or need to improve an existing design, our team has the expertise to transform your ideas into optimized designs ready for additive manufacturing. Contact us today to discuss your design needs and discover how our services can help bring your vision to life.