Additive manufacturing (DfAM)

Additive manufacturing represents a revolution in the design and fabrication of complex and customized components. At Kaplan Projects and Engineering, we are at the forefront of this technology, assessing its implementation on a case-by-case basis, ensuring it is applied only when there is real potential to do so over traditional manufacturing processes. In this way, we offer innovative solutions ranging from rapid prototyping to final parts.

Below, we present our services in this area:

Topology Optimization

We apply topology optimization techniques to design components with the minimal amount of material, maximizing strength and reducing weight, ideal for applications that require high efficiency and performance.

Generative Design

We use generative design to explore a wide range of potential structural and geometric solutions, based on project requirements to create innovative and optimized designs for additive manufacturing.

Lattice structures

We design lattice structures that provide a balance between weight, strength, and functionality. These structures are ideal for applications that require lightweight and strong materials, such as in aerospace or medical components.

Additive manufacturing technologies

Photopolymerization (SLA)

Photopolymerization, or Stereolithography (SLA), is a 3D printing technology that uses an ultraviolet laser to cure successive layers of photosensitive liquid resin. The process begins with projecting a light pattern onto the surface of the resin, solidifying only the exposed areas. Each cured layer adheres to the previous one, creating a solid piece layer by layer. This technology offers high precision and resolution, ideal for detailed prototypes and parts with superior surface finishes. Its use is common in the manufacturing of dental models, jewelry, and complex prototypes.

Powder Bed (SLM)

Laser melting in a powder bed, or Selective Laser Melting (SLM), is an additive manufacturing process that uses a high-power laser to melt metallic powder layer by layer. The powder is spread in a thin layer and fused by the laser according to the digital design. After each layer, a new layer of powder is added, and the process is repeated until the piece is complete. This method is ideal for producing complex metallic components with high density and outstanding mechanical properties, used in sectors such as aerospace, automotive, and medicine.

Binder Jetting is a 3D printing technology that uses a liquid binder to bond powder particles together to form a solid piece. The process involves the deposition of successive layers of powder and the application of a liquid binder that adheres the particles according to the design. Once the construction is complete, the piece is sintered or subjected to heat treatment to enhance its strength and properties. This method is versatile and can utilize a variety of materials, including metals, ceramics, and plastics, making it suitable for mass production and prototyping.

Binder Jetting
Material Extrusion (FDM)

Material Extrusion, or Fused Deposition Modeling (FDM), is a 3D printing technology that uses thermoplastic filaments that are melted and extruded through a heated nozzle to build a piece layer by layer. The material is deposited in a specific pattern, cooling and solidifying quickly upon contact with the previous layer. FDM is one of the most common and accessible technologies in 3D printing, used for creating functional prototypes and components with a wide range of mechanical properties. It is ideal for applications in engineering, industrial design, and education.