Software for designing additive manufacturing supports

Since additive manufacturing (AM) was invented there has been a disconnect between the design engineer’s vision and the physical printed part.

CAD vendors wrote CAD files for conventional manufacturing and AM machines are designed to receive STL files, which translate the design for the printing machine. They do marry, but they require a ‘mesh’ solution. Companies including Materialise and nettfab then began to offer an STL fixing function, as a translation stage. But it was still two communities working apart, said Danny Weber, vice-president Strategic Alliances at Stratasys.

“It was a broken system with no true integration.” Printed parts have big physical differences to machined and cast parts in terms of end of use. For example, metal 3D-printed parts with overhangs require supports, which need removal that can leave a residue. The core AM technology – material deposition – naturally leaves a lumpy or ‘rippled’ surface in many cases, which may be fine for applications such as prototypes but not for in-service, high-tolerance applications. High amounts of finishing can be required.