The DfAM strategy of redesigning multi-part assemblies into a single printed component, eliminating fasteners, reducing assembly time, and improving structural continuity.
Part consolidation is one of the highest-value DfAM strategies. Every eliminated fastener removes a failure mode, a tolerance stack-up, an assembly operation, and a purchased part. GE Aviation's fuel nozzle: 20 parts → 1 printed. Structural continuity eliminates joint stress concentrations.
Audit assemblies for: (1) parts that only exist to enable manufacturing (brackets, adapters, spacers), (2) fasteners that could be replaced by snap-fits or living hinges, (3) subassemblies joined only at interfaces. Redesign as monolithic geometry with internal channels and features.
Consolidated parts may require more support material and longer print time than individual parts. Serviceability suffers: a failed sub-feature means scrapping the whole part. Balance consolidation with repairability requirements.
Related terms: DfAM (Design for Additive Manufacturing), Snap Fit, Living Hinge, Assembly Clearance
| Field | engineering |
|---|---|
| Also called | assembly consolidation, part count reduction |
| Source | EDi Brain: rules-core |
Engineer, author of The Big Book of 3D Printing and additive manufacturing expert