Green Part Properties as Design Driver for “First Time Right” within sinter-based Additive Manufacturing introduced on the examples of Cold Metal Fusion and Metal FFF

Abstract

This paper examines features of parts manufactured via the processes cold metal
fusion (CMF) and metal fused filament fabrication (MFFF), which are both categorized as sinter
based additive manufacturing (SBAM) processes. The results of the investigations are a step
towards part design for “First Time Right”. Stresses induced by parts’ dead load are analyzed and
interpreted as a design driver. The differences in the failure behavior of parts from both
technologies are shown and discussed in the context of part design. In addition to the possibility
of evaluating conventionally designed SBAM parts, the findings also show potential for automated
part design. A load case is established to design parts suitable for debinding and sintering. The
findings are implemented in a case study in which an existing part is receiving a redesign via
topology-optimization.