Additive manufacturing - Design - Requirements, guidelines and recommendations (ISO/ASTM DIS 52910:2022)

Additive Fertigung - Konstruktion - Anforderungen, Richtlinien und Empfehlungen (ISO/ASTM DIS 52910:2022)

Fabrication additive - Conception - Exigences, lignes directrices et recommandations (ISO/ASTM DIS 52910:2022)

Aditivna proizvodnja - Konstruiranje - Zahteve, smernice in priporočila (ISO/ASTM DIS 52910:2022)

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Status
Not Published
Public Enquiry End Date
01-Oct-2022
Technical Committee
Current Stage
4020 - Public enquire (PE) (Adopted Project)
Start Date
02-Aug-2022
Due Date
20-Dec-2022
Completion Date
28-Oct-2022

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SLOVENSKI STANDARD
oSIST prEN ISO/ASTM 52910:2022
01-september-2022
Aditivna proizvodnja - Načrtovanje - Zahteve, smernice in priporočila (ISO/ASTM
DIS 52910:2022)
Additive manufacturing - Design - Requirements, guidelines and recommendations
Additive Fertigung - Konstruktion - Anforderungen, Richtlinien und Empfehlungen
Fabrication additive - Conception - Exigences, lignes directrices et recommandations
Ta slovenski standard je istoveten z: prEN ISO/ASTM 52910
ICS:
25.030 3D-tiskanje Additive manufacturing
oSIST prEN ISO/ASTM 52910:2022 en,fr,de
2003-01.Slovenski inštitut za standardizacijo. Razmnoževanje celote ali delov tega standarda ni dovoljeno.

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oSIST prEN ISO/ASTM 52910:2022

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oSIST prEN ISO/ASTM 52910:2022
DRAFT INTERNATIONAL STANDARD
ISO/ASTM DIS 52910
ISO/TC 261 Secretariat: DIN
Voting begins on: Voting terminates on:
2022-08-17 2022-11-09
Additive manufacturing — Design — Requirements,
guidelines and recommendations
Fabrication additive — Conception — Exigences, lignes directrices et recommandations
ICS: 25.030
This document is circulated as received from the committee secretariat.
THIS DOCUMENT IS A DRAFT CIRCULATED
FOR COMMENT AND APPROVAL. IT IS
ISO/CEN PARALLEL PROCESSING
THEREFORE SUBJECT TO CHANGE AND MAY
NOT BE REFERRED TO AS AN INTERNATIONAL
STANDARD UNTIL PUBLISHED AS SUCH.
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POTENTIAL TO BECOME STANDARDS TO
WHICH REFERENCE MAY BE MADE IN
Reference number
NATIONAL REGULATIONS.
ISO/ASTM DIS 52910:2022(E)
RECIPIENTS OF THIS DRAFT ARE INVITED
TO SUBMIT, WITH THEIR COMMENTS,
NOTIFICATION OF ANY RELEVANT PATENT
RIGHTS OF WHICH THEY ARE AWARE AND TO
PROVIDE SUPPORTING DOCUMENTATION. © ISO/ASTM International 2022

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oSIST prEN ISO/ASTM 52910:2022
ISO/ASTM DIS 52910:2022(E)
DRAFT INTERNATIONAL STANDARD
ISO/ASTM DIS 52910
ISO/TC 261 Secretariat: DIN
Voting begins on: Voting terminates on:

Additive manufacturing — Design — Requirements,
guidelines and recommendations
Fabrication additive — Conception — Exigences, lignes directrices et recommandations
ICS: 25.030
This document is circulated as received from the committee secretariat.
COPYRIGHT PROTECTED DOCUMENT
© ISO/ASTM International 2022 THIS DOCUMENT IS A DRAFT CIRCULATED
FOR COMMENT AND APPROVAL. IT IS
All rights reserved. Unless otherwise specified, or required in the context of its implementation, no part of this publication may
ISO/CEN PARALLEL PROCESSING
THEREFORE SUBJECT TO CHANGE AND MAY
be reproduced or utilized otherwise in any form or by any means, electronic or mechanical, including photocopying, or posting on
NOT BE REFERRED TO AS AN INTERNATIONAL
the internet or an intranet, without prior written permission. Permission can be requested from either ISO at the address below STANDARD UNTIL PUBLISHED AS SUCH.
or ISO’s member body in the country of the requester. In the United States, such requests should be sent to ASTM International.
IN ADDITION TO THEIR EVALUATION AS
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ISO copyright office ASTM International
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Email: copyright@iso.org Email: khooper@astm.org
NATIONAL REGULATIONS.
Website: www.iso.org Website: www.astm.org ISO/ASTM DIS 52910:2022(E)
RECIPIENTS OF THIS DRAFT ARE INVITED
Published in Switzerland
TO SUBMIT, WITH THEIR COMMENTS,
NOTIFICATION OF ANY RELEVANT PATENT
RIGHTS OF WHICH THEY ARE AWARE AND TO
ii
  © ISO/ASTM International 2022 – All rights reserved
PROVIDE SUPPORTING DOCUMENTATION. © ISO/ASTM International 2022

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oSIST prEN ISO/ASTM 52910:2022
ISO/ASTM DIS 52910:2022(E)
Contents Page
Foreword .iv
1 Scope . 1
2 Normative references . 1
3 Terms and definitions . 1
4 Purpose . 1
5 Design opportunities and limitations . 5
5.1 General . 5
5.2 Design opportunities . 6
5.3 Design limitations . . 7
6 Design considerations . 8
6.1 General . 8
6.2 Product considerations . 8
6.3 Product usage considerations . 9
6.3.1 General . 9
6.3.2 Thermal environment . . 9
6.3.3 Chemical exposure . 9
6.3.4 Radiation exposure . 9
6.3.5 Other exposure . 10
6.4 Sustainability considerations . . 10
6.5 Business considerations . 11
6.6 Geometry considerations .13
6.7 Material property considerations . 15
6.7.1 General .15
6.7.2 Mechanical properties . .15
6.7.3 Thermal properties . 16
6.7.4 Electrical properties . 16
6.7.5 Other . 16
6.8 Process considerations . 17
6.8.1 General . 17
6.8.2 Specific process considerations . 17
6.8.3 Other considerations . 19
6.9 Communication considerations . 19
7 Warnings to designers .20
Bibliography .22
iii
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oSIST prEN ISO/ASTM 52910:2022
ISO/ASTM DIS 52910:2022(E)
Foreword
ISO (the International Organization for Standardization) is a worldwide federation of national standards
bodies (ISO member bodies). The work of preparing International Standards is normally carried out
through ISO technical committees. Each member body interested in a subject for which a technical
committee has been established has the right to be represented on that committee. International
organizations, governmental and non-governmental, in liaison with ISO, also take part in the work.
ISO collaborates closely with the International Electrotechnical Commission (IEC) on all matters of
electrotechnical standardization.
The procedures used to develop this document and those intended for its further maintenance are
described in the ISO/IEC Directives, Part 1. In particular the different approval criteria needed for the
different types of ISO documents should be noted. This document was drafted in accordance with the
editorial rules of the ISO/IEC Directives, Part 2 (see www.iso.org/directives).
Attention is drawn to the possibility that some of the elements of this document may be the subject of
patent rights. ISO shall not be held responsible for identifying any or all such patent rights. Details of
any patent rights identified during the development of the document will be in the Introduction and/or
on the ISO list of patent declarations received (see www.iso.org/patents).
Any trade name used in this document is information given for the convenience of users and does not
constitute an endorsement.
For an explanation on the voluntary nature of standards, the meaning of ISO specific terms and
expressions related to conformity assessment, as well as information about ISO's adherence to the
World Trade Organization (WTO) principles in the Technical Barriers to Trade (TBT) see the following
URL: www.iso.org/iso/foreword.html.
This document was prepared by ISO/TC 261, Additive manufacturing, in cooperation with ASTM F42,
Additive Manufacturing Technologies, on the basis of a partnership agreement between ISO and ASTM
International with the aim to create a common set of ISO/ASTM standards on additive manufacturing.
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oSIST prEN ISO/ASTM 52910:2022
DRAFT INTERNATIONAL STANDARD ISO/ASTM DIS 52910:2022(E)
Additive manufacturing — Design — Requirements,
guidelines and recommendations
1 Scope
This document gives requirements, guidelines and recommendations for using additive manufacturing
(AM) in product design.
It is applicable during the design of all types of products, devices, systems, components or parts that
are fabricated by any type of AM system. This document helps determine which design considerations
can be utilized in a design project or to take advantage of the capabilities of an AM process.
General guidance and identification of issues are supported, but specific design solutions and process-
specific or material-specific data are not supported.
The intended audience comprises three types of users:
— designers who are designing products to be fabricated in an AM system and their managers;
— students who are learning mechanical design and computer-aided design;
— developers of AM design guidelines and design guidance systems.
2 Normative references
There are no normative references in this document.
3 Terms and definitions
For the purposes of this document, the terms and definitions given in ISO/ASTM 52900 apply.
ISO and IEC maintain terminological databases for use in standardization at the following addresses:
— ISO Online browsing platform: available at https:// www .iso .org/ obp
— IEC Electropedia: available at https:// www .electropedia .org/
4 Purpose
4.1 This document provides requirements, guidelines and recommendations for designing parts
and products to be produced by AM processes. Conditions of the part or product that favour AM
are highlighted. Similarly, conditions that favour conventional manufacturing processes are also
highlighted. The main elements include the following:
— the opportunities and design freedoms that AM offers designers (Clause 5);
— the issues that designers should consider when designing parts for AM, which comprises the main
content of these guidelines (Clause 6);
— warnings to designers, or “red flag” issues, that indicate situations that often lead to problems in
many AM systems (Clause 7).
4.2 The overall strategy of design for AM is illustrated in Figure 1. It is a representative process for
designing mechanical parts for structural applications, where cost is the primary decision criterion.
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The designer could replace cost with quality, delivery time, or other decision criterion, if applicable. In
addition to technical considerations related to functional, mechanical or process characteristics, the
designer should also consider risks associated with the selection of AM processes.
4.3 The process for identifying general potential for fabrication by AM is illustrated in Figure 2. This is
an expansion of the “identification of general AM potential” box on the left side of Figure 1. As illustrated,
the main decision criteria focus on material availability, whether or not the part fits within a machine’s
build volume, and the identification of at least one part characteristic (customization, lightweighting,
complex geometry) for which AM is particularly well suited. These criteria are representative of many
mechanical engineering applications for technical parts, but are not meant to be complete.
4.4 An expansion for the “AM process selection” box in Figure 1 is presented in Figure 3, illustrating
that the choice of material is critical in identifying a suitable process or processes. If a suitable
material and process combination can be identified, then consideration of other design requirements
can proceed, including surface considerations and geometry, static physical and dynamic physical
properties, among others. These figures are meant to be illustrative of typical practice for many types
of mechanical parts, but should not be interpreted as prescribing necessary practice.
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Figure 1 — Overall strategy for design for AM
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Figure 2 — Procedure for identification of AM potential
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oSIST prEN ISO/ASTM 52910:2022
ISO/ASTM DIS 52910:2022(E)
Material: metal
Powder bed Material
Main technical issues Material jetting Sheet lamination
fusion extrusion
Surface
Roughness
Staircase effect

Geometrical properties
Geometrical accuracy

Static physical properties
Porosity
Tensile strength
Ductility

Dynamic physical properties
Life cycle fatigue

Figure 3 — Parameters for the AM process selection
5 Design opportunities and limitations
5.1 General
Additive manufacturing differs from other manufacturing processes for several reasons and these
differences lead to unique design opportunities and freedoms that are highlighted here. As a general
rule, if a part can be fabricated economically using a conventional manufacturing process, that part
should probably not be produced using AM. Instead, parts that are good candidates for AM tend to have
complex geometries, custom geometries, low production volumes, special combinations of properties
or characteristics, or some combination of these characteristics. As processes and materials improve,
the emphasis on these characteristics will likely change. In Clause 5, some design opportunities are
highlighted and some typical limitations are identified.
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5.2 Design opportunities
5.2.1 Background — AM fabricates parts by adding material in a layer-by-layer manner. Due to the
nature of AM processes, AM has many more degrees of freedom than other manufacturing processes.
For example, a part can be composed of millions of droplets if fabricated in a material jetting
process. Discrete control over millions of operations at micro to nano scales is both an opportunity
and a challenge. Unprecedented levels of interdependence are evident among considerations and
manufacturing process variables, which distinguishes AM from conventional manufacturing processes.
Capabilities to take advantage of design opportunities can be limited by the complexities of process
planning.
5.2.2 Overview — The layer-based, additive nature means that virtually any part shapes can be
fabricated without hard tooling, such as moulds, dies or fixtures. Geometries that are customized to
individuals (customers or patients) can be economically fabricated. Very sophisticated geometric
constructions are possible using cellular structures (honeycombs, lattices, foams) or more general
structures. Often, multiple parts that were conventionally manufactured can be replaced with a single
part, or smaller number of parts, that is geometrically more complex than the parts being replaced.
This can lead to the development of parts that are lighter and perform better than the assemblies they
replace. Furthermore, such part count reduction (called part consolidation) has numerous benefits for
downstream activities. Assembly time, repair time, shop floor complexity, replacement part inventory
and tooling can be reduced, leading to cost savings throughout the life of the product. An additional
consideration is that geometrically complex medical models can be fabricated easily from medical
image data.
5.2.3 In many AM processes, material compositions or properties can be varied throughout a part.
This capability leads to functionally graded parts, in which desired mechanical property distributions
can be fabricated by varying either material composition or material microstructure. If effective
mechanical properties are desired to vary throughout a part, the designer can achieve this by taking
advantage of the geometric complexity capability of AM processes. If varying material composition or
microstructure is desired, then such variations can often be achieved, but with limits dependent on the
specific process and machine. Across the range of AM processes, some processes enable point-by-point
material variation control, some provide discrete control within a layer, and almost all processes enable
discrete control between layers (vat photopolymerization is the exception). In the material jetting and
binder jetting processes, material composition can be varied in virtually a continuous manner, droplet-
to-droplet or even by mixing droplets. Similarly, the directed energy deposition process can produce
variable material compositions by varying the powder composition that is injected into the melt pool.
Discrete control of material composition can be achieved in material extrusion processes by using
multiple deposition heads, as one example. Powder bed fusion (PBF) processes can have limitations
since difficulties can arise in separating unmelted mixed powders. It is important to note that specific
machine capabilities will change and evolve over time, but the trend is toward increasing material
composition flexibility and property control capability.
5.2.4 A significant opportunity exists to optimize the design of parts to yield unprecedented
structural properties. The concept of “design for functionality” can be realized, meaning that if a part’s
functions can be defined mathematically, the part can be optimized to achieve those functions. Novel
topology and shape optimization methods have been developed in this regard. Resulting designs can
have very complex geometric constructions, utilizing honeycomb, lattice or foam internal structures,
can have complex material compositions and variations, or can have a combination of both. Research is
needed in this area, but some examples of this are emerging.
5.2.5 Other opportunities involve some business considerations. Since no tooling is required for part
fabrication using AM, lead times can be very short. Little investment in part-specific infrastructure is
needed, which enables mass customization and responsiveness to market changes. In the case of repair,
remanufacturing of components could be highly advantageous both from cost as well as lead time
perspectives.
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5.3 Design limitations
5.3.1 Overview — It is useful to point out design characteristics that indicate situations when
AM should probably not be used. Stated concisely, if a part can be fabricated economically using
a conventional manufacturing process and can meet requirements, then it is not likely to be a good
candidate for AM. The designer should balance cost, value delivered and risks when deciding whether
to pursue AM.
5.3.2 A primary advantage of AM processes is their flexibility in fabricating a variety of part shapes,
complex and customized shapes, and possibly complex material distributions. If one desires mass
production of simple part shapes in large production volumes, then AM is not likely to be suitable
without significant improvements in fabrication time and cost.
5.3.3 A designer shall be aware of the material choices available, the variety and quality of feedstocks,
and how the material’s mechanical and other physical properties vary from those used in other
manufacturing processes. Materials in AM have different characteristics and properties because they
are processed differently than in conventional manufacturing processes. Designers should be aware
that the properties of AM components are highly sensitive to process parameters and that process
variability is a significant issue that can constrain freedom of design. Additionally, designers should
understand the anisotropies that are often present in AM processed materials. In some processes,
properties in the build plane (X, Y directions) are different than in the build direction (Z axis). With
some metals, mechanical properties better than wrought can be achieved. However, typically fatigue
and impact strength properties are not as good in AM processed parts in their as-built state as in
conventionally processed materials.
5.3.4 All AM machines discretize part geometry prior to fabricating a part. The discretization can
take several forms. For example, most AM machines fabricate parts in a layer-by-layer manner. In
material and binder jetting, discrete droplets of material are deposited. In other processes, discrete
vector strokes (e.g. of a laser) are used to process material. Due to the discretization of part geometry,
external part surfaces are often not smooth since the divisions between layers are evident. In other
cases, parts can have small internal voids.
5.3.5 Geometry discretization has several other effects. Small features can be ill-formed. Thin walls
or struts that are slanted, relative to the build direction, can be thicker than desired. Also, if the wall
or strut is nearly horizontal, the wall or strut can be very weak since relatively little overlap can occur
between successive layers. Similarly, small negative features such as holes can suffer the opposite
effect, becoming smaller than desired and having distorted shapes.
5.3.6 Post-processing is required for many AM processes or can be desired by the end user. A variety
of mechanical, chemical and thermal methods may be applied. Several AM process types utilize support
structures when building parts which need to be removed. In some cases, supports can be removed
using solvents, but in others the supports have to be mechanically removed. One should be aware of
the additional labour, manual component handling and time these operations require. Additionally,
designers should understand that the presence of support structures can affect the surface finish or
accuracy of the supported surfaces. In addition to support structure removal, other post-processing
operations can be needed or desired, including excess powder removal, surface finish improvement,
machining, thermal treatments and coatings. If a part has any internal cavities, the designer should
design features into the part that enable support structures, unsintered powder (PBF) or liquid resin
(VP) to be removed from those cavities. Depending on accuracy and surface finish requirements, the
part can require finish machining, polishing, grinding, bead blasting or shot-peening. Metal parts can
require a thermal treatment for relieving residual stresses, for example. Coatings can be required, such
as painting, electroplating or resin infiltration. Post processing operations increase the cost of AM
components.
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5.3.7 Each AM process has a limited build envelope. If a part is larger than the build envelope of an
AM process, then it can be divided into multiple parts, which are to be assembled after fabrication. In
some cases, this is not technically or economically feasible.
6 Design considerations
6.1 General
Several categories of design considerations have been identified, including product, usage, sustainability,
business, geometric, material property, process and communication considerations.
6.2 Product considerations
6.2.1 Design effectiveness — The designer can generate part shapes and configurations that optimize
performance and efficiency. Parts can be designed for desired properties, such as minimum weight,
maximum stiffness, etc., by designing shapes that are as efficient as possible. It can also be possible to
design a part to perform multiple functions, through the use of multiple materials, complex shapes or
part consolidation, which can have significant efficiency benefits.
6.2.2 Part or product consolidation — It is good design practice to minimize the number of parts in a
product or module, but no
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