Researchers at the University of West Attica have put forward a new framework that reimagines how products should be conceived for additive manufacturing, offering a broader and more integrated view of 3D-printing design. Published in Advanced Manufacturing, their work argues that traditional geometry-driven guidelines capture only a fragment of what is necessary for high-quality AM production. Instead, the authors propose that design must be grounded in a fuller understanding of process mechanics, material behaviour, and sustainability if additive manufacturing is to realise its potential as a mature production technology.

Although AM is now widely used in fields ranging from aerospace and medicine to automotive engineering, many design practices still reflect the assumptions of subtractive manufacturing. This mismatch between modern AM capabilities and inherited design habits forms the motivation for the study. The authors observe that 3D-printing processes involve complex interactions—thermal gradients during fabrication, anisotropic mechanical properties, bonding quality between layers, and the environmental implications of different material choices—that are often treated as secondary concerns. By overlooking these deeper process realities, designers risk creating parts that may be printable but fall short in performance, reliability, or lifecycle impact.

In their perspective article, “Toward a Holistic Approach for Design for Additive Manufacturing: A Perspective on Challenges, Practical Insights, and Research Needs,” the team outlines a shift toward system-level thinking. They contend that Design for Additive Manufacturing should not function as a checklist for avoiding print defects. Instead, it should integrate orientation strategies, tolerance planning, material-process coupling, and sustainability considerations from the very outset of design. Dr Kantaros emphasises that effective DfAM requires linking digital models with the physical constraints and behaviours of AM processes, enabling designs that are not only manufacturable but optimised for end-use performance.

The study critiques conventional geometry-focused DfAM approaches for failing to address issues such as thermal distortion, structural anisotropy, and recyclability. While geometry optimisation and topology tools have become increasingly sophisticated, they do not by themselves capture the full range of factors that govern part quality. The authors argue that designers must engage with simulation, process modelling, and multi-objective optimisation to understand better how design decisions influence physical outcomes.

To support this holistic view, the paper highlights the value of integrated digital workflows that combine simulation, AI-assisted manufacturability analysis, and iterative optimisation. Such environments allow designers to explore alternatives, predict potential failures, and evaluate trade-offs without excessive prototyping. This alignment between digital design and process physics, the authors claim, is central to unlocking more advanced applications.

The study also points to practical advantages of holistic DfAM, including part consolidation, mass customisation, and the use of functionally graded materials. These strategies show how AM can achieve significant improvements in performance, cost, and environmental impact when design and manufacturing are treated as interconnected stages. As Professor Theodore Ganetsos notes, meaningful innovation in additive manufacturing arises only when these domains merge, enabling sustainable, high-performance engineering solutions.

More information: Antreas Kantaros et al, Toward a holistic approach for design for additive manufacturing: a perspective on challenges, practical insights, and research needs, Advanced Manufacturing. DOI: 10.55092/am20250011

Journal information: Advanced Manufacturing Provided by ELSP