# Manufacturing

#### Introduction

When using the Diabatix platform for detailed designs, the generative design tool will create a design which is manufacturable. By doing so, you can push the limits of your design towards the limit of your manufacturing technique. The manufacturing settings can be managed through the libraries page. In the table below you can find a summary of the supported manufacturing techniques and their relevant parameters.

Manufacturing technique Parameters to set
CNC milling $$R_{f,min}$$
$$delta$$
$$orientation$$
Die casting $$R_{f,min}$$
$$R_{f,max}$$
$$b_{Ri}$$
$$b_{Ro}$$
$$angle$$
$$delta$$
$$orientation$$
3D printing $$R_{f,min}$$
Sheet metal forming $$R_{f,min}$$
$$R_{f,max}$$
$$b_{Ri}$$
$$b_{Ro}$$
$$t$$
$$angle$$
$$delta$$
$$orientation$$
Electric wire generation $$R_{f,min}$$

#### CNC milling

Parameter Unit Explanation
$$R_{f,min}$$ $$m$$ The minimum tool size.
• Cooling channels will have a width which is equal to or higher than this value.
• Corners will be rounded with a fillet radius which is equal to or bigger than this value.
$$delta$$ $$m$$ The depth of the cooling channels.
$$orientation$$ The orientation of the CNC milling axis. A 2D design will be created with the orientation axis as a normal.

#### Die casting

Parameter Unit Explanation
$$R_{f,min}$$ $$m$$ The minimum fin thickness.
$$R_{f,max}$$ $$m$$ The maximum fin thickness.
$$b_{Ri}$$ $$m$$ The inner bending radius.
$$b_{Ro}$$ $$m$$ The outer bending radius.
$$angle$$ $$°$$ The draft angle of the fins.
$$delta$$ $$m$$ The depth of the cooling channels.
$$orientation$$ The orientation of the demolding direction. A 2D design will be created whith the orientation axis as a normal.

#### 3D printing

Parameter Unit Explanation
$$R_{f,min}$$ $$m$$ The minimal printing resolution. All structures will have a width which is greater than this value
$$\alpha_{overhang}$$ $$°$$ The maximum allowed overhang angle. This property is by default set to 45°.
$$t_{support}$$ $$m$$ The thickness of the support structures. This property is by default set equal to the $$R_{f,min}$$ value.
$$l_{unsupported\:cantilever}$$ $$m$$ The maximum allowed unsupported cantilever length. This property is by default set to 2 millimeter.
$$l_{unsupported\:bridge}$$ $$m$$ The maximum allowed unsupported bridgeable length. This property is by default set to 4 millimeter.
$$orientation$$ The axis following the build-up direction of the additive manufacturing process. This property is by default set to the positive X-axis.

#### Sheet metal forming

Parameter Unit Explanation
$$R_{f,min}$$ $$m$$ The minimum channel width.
$$R_{f,max}$$ $$m$$ The maximum channel width.
$$b_{Ri}$$ $$m$$ The lower bending radius.
$$b_{Ro}$$ $$m$$ The upper bending radius.
$$t$$ $$m$$ The thickness of the stamped plate.
$$angle$$ $$°$$ The chamfer angle of the channels.
$$delta$$ $$m$$ The height of the fluid region.
$$orientation$$ The normal of the stamped plate.

#### Electric wire generation

Parameter Unit Explanation
$$R_{f,min}$$ $$m$$ The thickness of the generated electric wire.

When selecting the 'electric wire' manufacturing setting during the case setup, an additional field will appear asking you for a voltage. This is the voltage that will be put on the electric wire. Together with the material properties and the selected $$R_{f,min}$$, this puts a limit on the power outcome of the wire: $P = \frac{V^2}{\frac{\rho\space l}{\pi\space r^2}}$ Where:

• P represents the generated power in Watts [W]
• V represents the voltage on the wire in Volts [V]
• $$\rho$$ represents the resistivity of the material used in Ohm times meter [$$\Omega*m$$]
• $$l$$ is the length of the wire in meters [m], which has an upper limit based on the size of the design domain
• $$r$$ is the radius of the electric wire in meters [m]

This manufacturing technique is very different to the other ones. The design region that will come out of this optimization will have a heat source due to the Joule heating.

#### How to select the appropriate manufacturing settings for your design case setup?

The manufacturing type needs to be selected when setting up the design region. After selecting the manufacturing method, you need to select the manufacturing parameters. This can be a predefined set of parameters or you can add new set of parameters to the libraries.

⚠ Important
Note that an orientation should be specified. It is very important to look at the orientation of your model and make sure that the right orientation axis is selected!