Design for Modularity (DFM) Theory and Practice Modular Design of Giant 3D-Printer and 3D-Printed Products

Abstract:

Adapting to continuously changing needs and circumstances is a constant challenge for the designers of today. One possible solution to this is a flexible design, which can be effectively accomplished by a system of modular elements. A properly designed modular system can provide sufficient flexibility when configuring the product or equipment for the first time according to current needs. Furthermore, in case of changes in circumstances, the modular system can be easily reconfigured with another, optimized combination of elements according to the new needs. Modular design principles (DFM – Design for Modularity) is one focused direction of DFX techniques (DFX – Design for X) [1], which means design based on the modular principle. The paper presents modular design principles, methods and tools [2], which can be used to design modular equipment or modular product family. Reason for discussion is a running research project implemented by G-MAX Europe Ltd: development of a giant modular 3D printer (M3DP), project ID: 2021-1.1.4-GYORSÍTÓSÁV [3]. The research process can be divided into three parts. First is the design and construction of a prototype that is a large (5m x 1m x 1m workspace) modular 3D printer. Second part is the design of large-scale 3D printed products that can be manufactured by M3DP special machine. The 3D printing of these products must be feasible, reasonable and economical. The third part is the research and implementation of recycling-technology, since the machine must be able to produce a 3D printed product from 100% recycled raw materials. Professors, experts and specialists of the Technical University of Budapest; Faculty of Mechanical Engineering; Department of Machine and Product Design participated in the design of the research parts of the project. The paper further describes the modular machine family designed by the DfM method, including the modular element library system, the modular graph and the designed modules. Then some products will be presented that can be manufactured by the large M3DP equipment and can be flexibly selected or combined according to current requirements. During the design process, the principles and methods of Design for 3D printing (DF3DP), Design for Environment (DFE) and Design for Recycling (DFR) have been applied. For the development of the products, several small-scale mock-ups were 3D printed and tested used for iterations, to gain final and optimized product designs. In summary, the designers and researchers successfully fulfilled the very complex design and development tasks by a lot of research, simulations and experiments. The paper introduces the theory of DfM, presents the practical application, and certifies the adequacy by concrete examples.

• Periodical: Advances in Science and Technology (Volume 165)
• Pages: 67-80
• DOI: https://doi.org/10.4028/p-bkL5KG
• Online since: June 2025
• Authors: Viktor Gotthard*
• Keywords: 3D Printing, Additive Technology, Design For Modularity, Design For X, DFM, DFX, Giant 3D Printer, Modular Design, Modular Products

References

[1] Andreassen M. M., Multi product development: New models and concepts, 15. Symposium "Design for X" Neukirchen, October 14-15, (2004)

[2] Dr. Gotthard V., Theory and practice of modular design production lines, PhD study, BME, (2008)

[3] Information on http://www.g-max.hu/palyazat

[4] Information on http://www.sinuoph.com/Design/

[5] Gotthard V., Design for Flexibility, 5. Symposium "Design for X" Neukirchen, October 14-15, (2004)

[6] Information on http://www.3d-max.eu

[7] Gotthard V., Modular principle design (DFM) theory and practice: Modular design of giant 3D-printer and product development, XL. Conference of Machine and Product Designers Miskolc, November 7-8 (2024)

[8] Information on https://www.creality.com/products/creality-cr-30-3d-printer

[9] Information on https://www.3djake.com/spare-parts-upgrades/3d-printer-extruders

[10] Information on https://www.shapr3d.com/blog/design-for-3d-printing

[11] Information on https://www.3dnatives.com/en/3d-printed-boat-university-of-maine-161020195/