The Additive Mindset, Part 2: Combined Parts

The Additive Mindset, Part 2: Combined Parts

Previously, we wrote about designing for additive manufacturing, and how it requires a change of mindset to be most effective.

In this post we are exploring a major advantage of designing for additive that illustrates how a flexible mindset can have huge benefits for design and production. That advantage is the non-assembled part. A single non-assembled part is comprised of multiple elements combined together. The key is that each element would have been made separately and then fastened together later in a typical injection molding project.

As an example, take a look at the headband we designed for the CGX Quick-32r EEG headset. Look closely and you’ll see that in reality it’s much more than just a headband; it is composed of a housing for electronics at the top, another similar housing on each end, the headband itself (which connects the three housings together), and an internal platform within the headband on which a flexible circuit rests in the final assembly. Each of these elements would have existed as its own, separate part if this project had been cast or injection molded.

The advantages to combining parts for additive manufacturing in this way are numerous. Here are a few key examples:

1.    Eliminate the expense and delay of tooling: for example, the headband we show here would have required at least seven separate injection molds.

2.      Reduce labor and assembly costs: no need for fasteners and the time and expense of assembly labor, resulting in streamlined lead times and budgets.

3.      Design freedom to incorporate features that would be impossible with traditional injection molding.

We hope this helps give a concrete example of how designing with an awareness of the capabilities of additive manufacturing can provide a huge benefit to a project. We will continue to explore the additive mindset in future posts.