Design for Direct Digital Manufacturing Competition

Design a product that illustrates the benefits and impacts of direct digital manufacturing.

For 2012, student designers are to use their imagination to design a product that mainly utilizes DDM processes. The product must be able to be used in another assembly.

The designed product will be a device, mechanism, assembly or a subassembly representing part of another product. The resultant design should represent a fully working prototype. Any internal electronics or mechanics must be specified within the design. The geometry of the design must be defined within a three-dimensional (3-D), computer-aided design (CAD) system capable of producing robust STL files.

Direct digital manufacturing using additive manufacturing has several advantages: (1) parts can be virtually any shape; (2) the need for subassemblies is reduced due to the integration of multiple parts into one; and (3) parts can be highly customized to a user's specifications without the need for individualized tooling.

As the designer, the primary limitation on how well DDM is exploited depends on how imaginative you can be!

Click here to view the winning entries from the 2011 competition.

Entries are welcome from both college/university students and high school students. The two categories will be judged separately according to the following weighted criteria:

Criteria	Weight of Criteria
Functionality impact analysis	20%
Cost/benefit analysis	15%
Justification of DDM material	15%
Justification of DDM process	15%
Component integration	15%
Innovative geometrical features via DDM	10%
Judge's discretion	10%
	Total 100%

Each category submission will consist of a zipped file, which includes:

1. A completed 2012 entry form.
2. An STL file(s) of your design.
3. A one-page summary stating why your design is suited for DDM.
   • Include the benefits your design would bring to the customer.
   • Indicate the volume of the build.
   • Include your name(s) and contact information.
   • Include your school name along with the name of your academic advisor as well as his/her e-mail address in addition to the title of your entry.

In addition, college/university entrants will also need to submit a three-page report containing the following additional elements:

1. Justified choices of DDM processes and materials to be used.
2. Environmental impact analysis.
3. A cost-benefit analysis for using DDM (include an estimate of the quantity to be manufactured).
4. Include your name(s) and contact information.
5. Include your school name along with the name of your academic advisor including his/her e-mail address in addition to the title of your entry.

Submissions must be made using the following process:

1. Complete your design in a 3-D system that can provide an STL format file as well as a STEP file.
2. Complete the 2012 entry form.
3. Complete a one-page summary stating why your design is suited for DDM.
4. Include a rendering or JPEG photo of the completed design.
5. College and university entrants must also include the three-page report.
6. Save the entry form, summary page, STL file and report (if applicable) in a zipped file.
7. Upload the zipped file containing all forms, reports and design to
   met-l-flo.com/ftp.asp  
8. In the "Comments" section, enter "2012 DDM Competition."
9. Wait for the upload confirmation.**
10. Submit all forms and files prior to the April 23, 2012, deadline. Entries will be judged by April 30, 2012, and winners will be notified shortly thereafter. An announcement of the winners and runners-up will be made at SME's annual RAPID Conference & Exposition, held May 22-25 2012, in Atlanta.
    
    Questions regarding the final submission or any other aspect of the competition and can be sent to:
    
    Peter Ried Jr.
    Secretary
    DDM Tech Group

First Prize (One university winner and one high school winner)
The designer* whose design is judged as being the best example of how DDM can be fully exploited will receive:

• A complimentary conference pass to the 2012 RAPID Conference & Exposition.
• A stipend of $300 to use for travel and lodging to the conference.
• A personalized recognition award (awarded May 24, 2012, during the Plenary Session).
• A certificate of achievement.
• A complimentary, one-year SME student membership.
• An SME logo gift.
• A recognition letter sent to the winner with a copy sent to the university advisor/employer.
• A recognition letter sent to a student newspaper/technical publication designated by the winner.

*Only one (1) individual in each category will be awarded first prize. If the design is submitted by more than one individual, the designated leader will receive the total prize and any co-designer(s) will receive a certificate of achievement only.

 

Runners-Up

Second and third-place winners in each category will receive:

• A certificate of achievement
• A complimentary, one-year SME student membership

*Only one (1) individual from each category will be awarded the prize for second place and one for third place. If the design is submitted by more than one individual, the designated leader will receive the total prize and any co-designer(s) will receive a certificate of achievement only.

In addition, the winning design and two runners-up will be manufactured using DDM technology. The models will be presented to the student who designed them (or an individual representative of a design team). All design entries may be used in future publicity by SME and other organizers of the competition. The competition review committee will be comprised of members of the RTAM/SME's Direct Digital Manufacturing Tech Group.

Note: Design teams are restricted to a maximum of four (4) members per team.

The first-place winner in both categories will have the opportunity to present their project during the DDM Tech Group Meeting being held onsite at the 2012 RAPID Conference & Exposition.

**Judging may be subject to change based upon the number of entries received.
*** All college/university teams' submittals must be complete, or the submittal may not be considered.