New framework emphasizes system-level approach to DfAM, integrating design intent, material behavior, and sustainability.
For 3D printing, the journey from prototyping to full production—aka additive manufacturing (AM)—is long, arduous, and still very much ongoing. However, one of the key insights that’s emerged over the past few decades is that unlocking the full capabilities of this technology requires a new approach from the ground up. In a word (okay, four words), it requires design for additive manufacturing (DfAM).
While this approach is likely natural for the majority of the newest generation of engineers, many the old guard may still need convincing, including an appreciation for the differences between DfAM and design for manufacturing (DFM) more generally.
But even if DfAM is a core part of your engineering umwelt, it’s important to recognize that this once novel concept is also still evolving. Enter a new paper from researchers at the University of West Attica in Greece, which proposes a “system-level and process-aware design mindset” that aims to take engineers beyond the basic physics and geometry of 3D printing to integrate design intent, material behavior, and sustainability into a more holistic DfAM model.
“Design for Additive Manufacturing should not merely ensure printability,” said lead author Antreas Kantaros in a press release. “It must connect material-process interactions, build orientation, tolerancing, and sustainability considerations to create designs that are innovative, reliable, and efficient.” Kantaros is a materials scientist in the department of industrial design and production engineering and, according to his LinkedIn page, he was among the World’s Top 2% Scientists in 2024.
The paper critiques existing DfAM methods that focus mainly on geometry optimization, arguing that such heuristics overlook critical factors such as anisotropy, thermal distortions, and lifecycle sustainability. As a solution, the authors advocate for an integrated workflow which combines simulation, optimization, and AI-assisted manufacturability feedback within digital design environments.
To support their claims, Kantaros and his colleagues cite part consolidation, mass customization, and functionally graded materials as applications that demonstrate how their holistic DfAM thinking can improve product performance while reducing environmental impact and production costs.
“True innovation in additive manufacturing begins when design and manufacturing are no longer treated as separate stages,” said professor and co-author Theodore Ganetsos. “By merging these perspectives, we can achieve sustainable, high-performance engineering solutions.”
The paper, entitled “Toward a Holistic Approach for Design for Additive Manufacturing: A Perspective on Challenges, Practical Insights, and Research Needs,” is published under a Creative Commons license in the journal Advanced Manufacturing.
