In this geometry complexity study, an electronics enclosure is redesigned for RM to identify potential performance improvements and costs reduction.
Case study: design study of avionics enclosure
Even though IMAdMan usually focuses on metal-based AM, in this scenario, we step away from metal SLM to concentrate on plastic SLS as this material exhibits properties better suited to the final application.
Given the (lack of proper) budget and the short design-to-delivery timeframe (2 weeks), SLS is preferred to injection molding.
In this scenario, the design has to comply with stringent temperature, vibrations and stress requirements outlined by the customer. Easy installation and secure fastening of electrical and electronics components drive the design, starting with the outer geometrical shape that has to be fitted in the front of the UAV. The inner features of the casing are designed used parametric CAD software.
Some challenges remain such as a lack of (certified) material data specification describing mechanical behaviour. As a result, the actual part required expensive testing following manufacturing. Significantly reduced electromagnetic interferences compensated for these additional testing costs.
Following this study, specific re-design and use of SLS was also successfully employed on a follow-up project , and has since established itself as the way to produce deliverable, performance enclosures specifically for UAVs. 
 M. J. Burton, “Design for rapid manufacture : developing an appropriate knowledge transfer tool for industrial designers,” Loughborough University, 2005.
 S. Maidin, R. I. Campbell, I. Drstvensek, and P. Sever, “Design for rapid manufacturing – capturing designers ’ knowledge,” in Advanced Research in Virtual and Rapid Prototyping - Proceedings of VR@P4, 2009, pp. 311–317.
 P. du Plessis, “A Functional Application Of RM In A Military Environment,” in TCT Conference, 2008.
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