Multiple → one.
Reduce assembly.
Cost reduction.
Part consolidation reference. Combine multiple parts into single piece. Reduces fasteners, assembly labor, supply chain. Common DFM optimization.
Key principles.
3D printing enables
3D printing enables complex geometry impossible to machine.
Cast geometry
Cast complex shapes. Reduces multi-piece assembly.
Multi-shot
Multi-shot injection combines materials in single part.
Trade-offs
Weld assemblies vs single-piece machining. Cost crossover.
Eliminate fasteners
Snap-fit features eliminate fasteners.
Supply chain
Fewer SKUs, simpler supply chain.
FAQ
When does consolidation pay?
Multi-piece assembly with significant labor. 3D printing enables once-impossible consolidation.
Cost calculation?
Material + processing per consolidated part. vs Material + processing × multiple parts + assembly + fasteners.
Topology optimization?
Generative design + 3D printing creates organic optimal shapes. Aerospace, medical applications.
Risk?
Single-piece failure replaces full assembly. Multi-piece allows individual replacement. Trade-off.
Production volumes?
Low volume: consolidation 3D printing wins. High volume: traditional manufacturing scales.
Examples?
Aerospace brackets, medical implants, automotive structural parts. 30-70% mass/cost savings typical.
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