This article focuses on the design and manufacture of mechanical parts that have complicated shapes using the technique of reverse design using a scanner or an MMT for data acquisition in the form of a point cloud, using CAD software (CATIA). The digital model created is used for a virtual representation of the final product. Then we get the physical model on a 3D printer (also called additive manufacturing process) for later use in sand moulds. To have the imprint in the sand mould, we go through the fusion of the physical model (part). The use of this technique in the industry, allows us to save a lot of time in terms of model preparation and simple to implement, especially if it is mechanical parts that do not have a definition drawing, or they are worn out, then structural analysis was applied on the model using FE based software and tools to prove the quality of the product. Von Mises equivalent strains and stresses were predicted and decreased with increasing areas and honeycomb thickness. The objective of this article is to give an overview of this relatively modern technology and its various applications.

The presence of geometric discontinuity in a material reduces considerably its resistance to mechanical stresses, therefore reducing the service life of materials. The analysis of structural behaviour in the presence of geometric discontinuities is important to ensure the proper use, especially if it is regarding a material of weak mechanical properties such as a polymer. The objective of the present work is to analyse the effect of the notch presence of variable geometric shapes on the tensile strength of epoxy-type polymer specimens. A series of tensile tests were carried out on standardised specimens, taking into account the presence or absence of a notch. Each series of tests contains five specimens. Two notch shapes were considered: circular (hole) and elliptical. The experimental results in terms of stress–strain clearly show that the presence of notches reduces considerably the resistance of the material, where the maximum stress for the undamaged specimen was 41.22 MPa and the lowest stress for the elliptical-notched specimen was 11.21 MPa. A numerical analysis by the extended finite element method (XFEM) was undertaken on the same geometric models; in addition, the results in stress–strain form were validated with the experimental results. A remarkable improvement was obtained (generally an error within 0.06%) for strain, maximum stress, Young’s modulus and elongation values. An exponential decrease was noted in the stress, strain, and Young’s modulus in the presence of a notch in the material.