Product DESIGN TIPS
Core Principles for Rapid Prototyping
Function-Driven Design
Critical Validation Goals: Prioritize core functional validation (structural integrity, assembly tolerance, motion testing). Eliminate non-functional aesthetic features.
Simplified Geometry: Retain only geometry critical to functional verification.
Modular Design: Split complex assemblies into testable subcomponents for phased validation.
Process-Specific Optimization
| Process | Best Applications | Materials | Tolerance |
|---|---|---|---|
| 3D Printing (SLA/DLP) | Complex curves, thin walls | Resins, Nylon | ±0.1-0.3mm |
| CNC Machining | High-precision metals/hard plastics | Aluminum, PEEK, ABS | ±0.05-0.1mm |
| Silicone Molding | Low-volume (<100pcs) soft/clear parts | Silicone, PU resin | ±0.2mm |
Process Limitations:
- 3D Printing: Avoid overhangs >45° without supports or split designs.
- CNC: Add R≥3mm fillets to deep cavities; avoid sharp blind holes.
Design Optimization Techniques
Structural Guidelines
Plastics: 1.5-4mm (2.5mm avg; min 0.8mm locally)
Metals: ≥1mm (Ti/Al alloys); ≥2mm (stainless steel)
Thinner walls risk warping; thicker walls increase cost/weight
Rib Design:
Rib thickness ≤60% of main wall; height ≤5x wall thickness
Add R0.5-1mm fillets at rib roots to prevent stress concentration
Assembly Interface Design
Alignment Features:
- Use tapered pins (1-2° draft) instead of cylindrical pins for tolerance compensation
- Snap-fit joints: Allow 0.2-0.5mm elastic deformation space
Thread Solutions:
- Printed/machined threads: Suitable for M3+; depth ≤3x diameter
- Inserted brass threads: Design Φ(hole+0.5mm)×depth slots
Material & Finishing Selection
| Application | Recommended Materials | Key Properties |
|---|---|---|
| High-strength structures | 6061 Aluminum/Glass-filled PA12 | Tensile strength >200MPa |
| High-temp testing (>150°C) | PEEK/Ultem 1010 | HDT@260°C/Tg 217°C |
| Optical/transparent verification | PMMA/Transparent resin | Light transmission >90% |
| Flexible/wear-resistant | TPU/Silicone | Shore A50-90 adjustable |
Blasting/Polishing:
- Use: Improve surface finish (Ra 0.8→0.2μm) on metals/resins
- Caution: May reduce dimensional accuracy by ±0.05mm
Plating/Coating:
- Metals: Anodizing (corrosion resistance), nickel plating (conductivity)
- Plastics: UV coating (scratch resistance), metallic paint
Cost Control Strategies
Design-Stage Savings
Reduce Machining Time:
Consolidate CNC operations in the same orientation to minimize setups
Use 20-50% infill density for 3D-printed hollow structures
Standardized Components:
Adopt M3/M4 fasteners, 608ZZ bearings, etc.
Batch Optimization
| Process | Cost-Effective Batch |
|---|---|
| 3D Printing | 1-50pcs |
| Silicone Molding | 50-300pcs |
| CNC Low-Volume | 300-1,000pcs |
