Design for Additive Manufacturing (DfAM) is designing so you exploit the benefits of 3D printing instead of copying classic restrictions. Use geometric freedom, integrate functions, optimise weight through lattices or topology optimisation. And factor in SLS-specific concerns like wall thickness, orientation and heat management.
Why DfAM is more than "print what you have"
Many companies start with 3D printing by uploading an existing CAD file. It works technically, but 30-60% saving potential stays on the table.
Classic CAD is designed inside CNC or moulding restrictions: uniform wall, no cavities, tool access, demoulding angles. If you lift those, the optimal design changes fundamentally. Where CNC is solid, SLS can go with internal lattices. Where injection moulding needs demoulding angles, SLS walls can be perfectly vertical.
Five pillars of DfAM for SLS
Geometric freedom. Complex internal channels, cavities, undercuts, organic shapes. At no extra cost.
Function integration. Assemblies as a single print.
Lattice and topology optimisation. Skeletal structures 40-60% lighter, same load capacity.
Orientation-aware design. Critical dimensions and load directions modelled with build direction.
Material match. Choose material (PA12, PA11, Carbon LW, PA802CF) based on load case, not default.
How to get started
For one prototype, digging deep into DfAM rarely pays. Let the first iteration print as you have it.
The moment you decide on a run or recurring geometry: ask for our DfAM check. Our engineers walk through your STEP on wall thickness, stress concentrations, integration options and orientation effects. Within one working day you have concrete recommendations, often with visual markers on the CAD model.
For larger projects: extended DfAM consult together across your whole production portfolio.