oSIST prEN ISO/ASTM 52910:2022

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)

General Information

• Status: Not Published
• Public Enquiry End Date: 01-Oct-2022
• ICS: 25.030 - Additive manufacturing
• Technical Committee: VAR - Welding
• Current Stage: 4020 - Public enquire (PE) (Adopted Project)
• Start Date: 02-Aug-2022
• Due Date: 20-Dec-2022
• Completion Date: 28-Oct-2022
• Ref Project: prEN ISO/ASTM 52910 - Additive manufacturing - Design - Requirements, guidelines and recommendations (ISO/ASTM DIS 52910:2022)

Relations

• Revised: SIST EN ISO/ASTM 52910:2019 - Additive manufacturing - Design - Requirements, guidelines and recommendations (ISO/ASTM 52910:2018)
• Effective Date: 01-Sep-2022

Standards Content (Sample)

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
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NOT BE REFERRED TO AS AN INTERNATIONAL
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NATIONAL REGULATIONS.
ISO/ASTM DIS 52910:2022(E)
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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
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RECIPIENTS OF THIS DRAFT ARE INVITED
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PROVIDE SUPPORTING DOCUMENTATION. © ISO/ASTM International 2022
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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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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.

© ISO/ASTM International 2022 – All rights reserved
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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.

© ISO/ASTM International 2022 – All rights reserved
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Figure 1 — Overall strategy for design for AM
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ISO/ASTM DIS 52910:2022(E)
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
...