Design for Additive Manufacturing: Recent Innovations and Future Directions

Abstract

Design for additive manufacturing (DfAM) provides a necessary framework for using novel additive manufacturing (AM) technologies for engineering innovations. Recent AM advances include shaping nickel-based superalloys for lightweight aerospace applications, reducing environmental impacts with large-scale concrete printing, and personalizing food and medical devices for improved health. Although many new capabilities are enabled by AM, design advances are necessary to ensure the technology reaches its full potential. Here, DfAM research is reviewed in the context of Fabrication, Generation, and Assessment phases that bridge the gap between AM capabilities and design innovations. Materials, processes, and constraints are considered during fabrication steps to understand AM capabilities for building systems with specified properties and functions. Design generation steps include conceptualization, configuration, and optimization to drive the creation of high-performance AM designs. Assessment steps are necessary for validating, testing, and modeling systems for future iterations and improvements. These phases provide context for discussing innovations in aerospace, automotives, construction, food, medicine, and robotics while highlighting future opportunities for design services, bio-inspired design, fabrication robots, and machine learning. Overall, DfAM has positively impacted diverse engineering applications, and further research has great potential for driving new developments in design innovation.

Effect of Sterilization on the Dimensional and Mechanical Behavior of Polylactic Acid Pieces Produced by Fused Deposition Modeling

“…Additive manufacturing approaches have emerged as promising tools to address the abovementioned shortcomings. Among these technologies, fused deposition modeling has drawn special attention due to its inexpensive nature and the fact that it allows both the extrusion of a wide range of polymers, such as PLA [ 16 , 17 ], as well as the fabrication of highly complex structures [ 18 ]. The latter becomes key to surgical scenarios that require patient-specific devices.…”

“…To overcome these obstacles, additive manufacturing (AM) has emerged as a sustainable production alternative for customized MDs. Particular attention has been focused on the use of fused deposition modeling (FDM) due to its inexpensive nature, as well as the fact that it allows both the extrusion of a wide range of polymers, such as PLA [ 16 , 17 ], and the fabrication of highly complex structures [ 18 ]. The latter becomes key to surgical scenarios that require patient-specific devices [ 16 , 19 ].…”

“…Particular attention has been focused on the use of fused deposition modeling (FDM) due to its inexpensive nature, as well as the fact that it allows both the extrusion of a wide range of polymers, such as PLA [ 16 , 17 ], and the fabrication of highly complex structures [ 18 ]. The latter becomes key to surgical scenarios that require patient-specific devices [ 16 , 19 ]. In this sense, from cranioplasty implants [ 20 ] and screw guides for spine surgery [ 21 ] to chest wall reconstruction devices [ 22 ], FDM has been successfully tested in the clinical setting.…”

Critical Review of Comparative Study of Selective Laser Melting and Investment Casting for Thin-Walled Parts

“…Each method offers distinct advantages, making it a complex decision that depends on specific project requirements and constraints. The final choice should align with the desired outcome and resource allocation [67]. Both SLM and investment casting, despite their intrinsic disparities, find their niche in addressing the complex needs of these industries.…”

Innovative Approaches to 3D Printing of PA12 Forearm Orthoses: A Comprehensive Analysis of Mechanical Properties and Production Efficiency

“…It is worth noting that the components shown in the benchmark were designed per the Design for Additive Manufacturing methodology, which focuses on consolidating multiple components into a single functional object and using lattice structures [96].…”