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The purpose of this paper is to propose a method to obtain hybrid rapid tools with elementary component assembly.

The authors' method proposes a functional representational model, starting with the product features, analyzed from three points of view: a feasibility analysis; a manufacturing analysis; and an assembly and synthesis analysis. This method, based on CAD STEP AP‐224 data, makes it possible to obtain an exhaustive list of solutions for the module. The work is illustrated with an industrial example. To construct the Assembly Identity Card (AIC) and test the various parameters that influence the quality of the injected parts, a hybrid injection mold has been produced. The methodology associated with the use of this AIC uses a “representation graph”, which makes it possible to propose a set of valid solutions for assembling the various tooling modules. This method is validated by industrial example.

The product part is decomposed into a multi‐component prototype (MCP), instead of being made as a single part, which optimizes the manufacturing process and enables greater reactivity during the development of the product.

The final goal is to propose a software assistant used in association with CAD system during the design of hybrid rapid tooling. An important work concerning the features recognition must be implemented. The assembly of the different parts of the hybrid rapid tooling must be considered and optimized.

This method allows the selection of the best process technologies from manufacturing tools.

The analysis of manufacturing hybrid rapid tooling has not been studied previously.

One major problem preventing further application and benefits from additive manufacturing (AM) nowadays is that AM build parts always end up with poor geometrical quality. To help improving geometrical quality for AM, this study aims to propose geometrical deviation identification and prediction method for AM, which could be used for identifying the factors, forms and values of geometrical deviation of AM parts.

This paper applied the skin model-based modal decomposition approach to describe the geometrical deviations of AM and decompose them into different defect modes. On that basis, the approach to propose and extend defect modes was developed. Identification and prediction of the geometrical deviations were then carried out with this method. Finally, a case study with cylinders manufactured by fused deposition modeling was introduced. Two coordinate measuring machine (CMM) machines with different measure methods were used to verify the effectiveness of the methods and modes proposed.

The case study results with two different CMM machines are very close, which shows that the method and modes proposed by this paper are very effective. Also, the results indicate that the main geometrical defects are caused by the shrinkage and machine inaccuracy-induced errors which have not been studied enough.

This work could be used for identifying and predicting the forms and values of AM geometrical deviation, which could help realize the improvement of AM part geometrical quality in design phase more purposefully.

There are many investigations in design methodologies, but there are also divergences and convergences as there are so many points of view. This study aims to evaluate to corroborate and deepen other researchers’ findings, dissipate divergences and provide directing to future work on the subject from a methodological and convergent perspective.

This study analyzes the previous reviews (about 15 reviews) and based on the consensus and the classifications provided by these authors, a significant sample of research is analyzed in the design for additive manufacturing (DFAM) theme (approximately 80 articles until June of 2017 and approximately 280–300 articles until February of 2019) through descriptive statistics, to corroborate and deepen the findings of other researchers.

Throughout this work, this paper found statistics indicating that the main areas studied are: multiple objective optimizations, execution of the design, general DFAM and DFAM for functional performance. Among the main conclusions: there is a lack of innovation in the products developed with the methodologies, there is a lack of exhaustivity in the methodologies, there are few efforts to include environmental aspects in the methodologies, many of the methods include economic and cost evaluation, but are not very explicit and broad (sustainability evaluation), it is necessary to consider a greater variety of functions, among other conclusions

The novelty in this study is the methodology. It is very objective, comprehensive and quantitative. The starting point is not the case studies nor the qualitative criteria, but the figures and quantities of methodologies. The main contribution of this review article is to guide future work on the subject from a methodological and convergent perspective and this article provides a broad database with articles containing information on many issues to make decisions: design methodology; optimization; processes, selection of parts and materials; cost and product management; mechanical, electrical and thermal properties; health and environmental impact, etc.

To propose a method to manufacture a hybrid rapid tool (a multi component tool).

The part is decomposed into multi component prototype instead of a part made from a single piece. First, this method is based on a topological analysis of the tool. Features are regrouped starting from the numerical definition of the die. Second, the manufacturing possibilities of the high speed milling (HSM), direct metal laser sintering (DMLS) and electro discharge machining (EDM) process are analyzed. Finally this information is synthesized to obtain solutions. This method is validated by industrial example.

A method is proposed to choose the best manufacturing process in order to optimize the manufacture of a “hybrid rapid tooling” between three processes: HSM, DMLS and EDM. So, it is possible to obtain the different components of the hybrid rapid tooling according to the envisaged process.

The final goal is to propose a software assistant used in association with CAD system during the design of hybrid rapid tooling. An important work concerning the features recognition must be implemented. The assembly of the different parts of the hybrid rapid tooling must be considered and optimized.

This method allows the selection of the best process among EDM, HSM and DMLS technologies form manufacturing tools.

The analysis of manufacturing hybrid rapid tooling has not been studied yet.

The purpose of this paper is to understand how Design for Additive manufacturing Knowledge has been developing and its significance to both academia and industry.

In this paper, the authors use a bibliometric approach to analyse publications from January 2010 to December 2020 to explore the subject areas, publication outlets, most active authors, geographical distribution of scholarly outputs, collaboration and co-citations at both institutional and geographical levels and outcomes from keywords analysis.

The findings reveal that most knowledge has been developed in DfAM methods, rules and guidelines. This may suggest that designers are trying to learn new ways of harnessing the freedom offered by AM. Furthermore, more knowledge is needed to understand how to tackle the inherent limitations of AM processes. Moreover, DfAM knowledge has thus far been developed mostly by authors in a small number of institutional and geographical clusters, potentially limiting diverse perspectives and synergies from international collaboration which are essential for global knowledge development, for improvement of the quality of DfAM research and for its wider dissemination.

A concise structure of DfAM knowledge areas upon which the bibliometric analysis was conducted has been developed. Furthermore, areas where research is concentrated and those that require further knowledge development are revealed.

Dual design for additive manufacturing (DfAM) takes into account both the opportunities and constraints of AM simultaneously, which research shows is more effective than considering them separately. Unlike existing reviews, this paper aims to map DfAM research within the engineering design process, focusing solely on studies adopting dual DfAM. Additionally, it aims to suggest future research directions by analysing prominent research themes and their inter-relationships. Special emphasis is on theme inter-relationships concerning the conceptual, embodiment and detail design phases.

The study is based on a systematic literature review of 148 publications from January 2000 to February 2024. After screening, prominent research themes were identified and systematically analysed. Theme inter-relationships were explored using quantitative analysis and chord diagrams.

The findings reveal that studies either span the entire design process, the early design phases or the later design phases. Most research focuses on the later design phases, particularly within themes of design optimisation, design evaluation and AM-specific manufacturing constraints. The most frequent theme inter-relationship occurs between design optimisation and AM-specific manufacturing constraints. Overall, the findings suggest future research directions to advance dual DfAM research, such as development of design rules and guidelines for cellular structures.

This review proposes a model by mapping prominent themes of dual DfAM research in relation to the engineering design process. Another original contribution lies in analysing theme inter-relationships and visualising them using chord diagrams – a novel approach that did not exist before.

This paper aims to review recent research in design for additive manufacturing (DfAM), including additive manufacturing (AM) terminology, trends, methods, classification of DfAM methods and software. The focus is on the design engineer’s role in the DfAM process and includes which design methods and tools exist to aid the design process. This includes methods, guidelines and software to achieve design optimization and in further steps to increase the level of design automation for metal AM techniques. The research has a special interest in structural optimization and the coupling between topology optimization and AM.

The method used in the review consists of six rounds in which literature was sequentially collected, sorted and removed. Full presentation of the method used could be found in the paper.

Existing DfAM research has been divided into three main groups – component, part and process design – and based on the review of existing DfAM methods, a proposal for a DfAM process has been compiled. Design support suitable for use by design engineers is linked to each step in the compiled DfAM process. Finally, the review suggests a possible new DfAM process that allows a higher degree of design automation than today’s process. Furthermore, research areas that need to be further developed to achieve this framework are pointed out.

The review maps existing research in design for additive manufacturing and compiles a proposed design method. For each step in the proposed method, existing methods and software are coupled. This type of overall methodology with connecting methods and software did not exist before. The work also contributes with a discussion regarding future design process and automation.

Additive manufacturing technology significantly simplifies the production of complex three-dimensional (3 D) parts directly from the computer-aided design (CAD) model. Although additive manufacturing (AM) processes have unexampled flexibility, they still have restrictions inhibiting engineers to easily generate some specific geometric shapes, easily. Some of these problems pertain to the consumption of materials as supports, the inferior surface finish of some surfaces with certain angles, etc. One of the approaches to overcome these problems is designing by segmentation.

The proposed methodology consists of two steps: (1) segmentation of the 3 D model and (2) exploring the best orientation for each segment. In the first step, engineers consider the possible number of segments and the connection method of segments. In this paper, a series of segments, called a segmentation pattern (SP), is obtained by the recognition of features and separating them automatically (or manually when needed) with one or more appropriate planes. In the second step, the best fabrication orientation should be chosen. The criteria for choosing the best SP and OPs are minimizing the support volume, building time (directly affected by segments’ height in layer-wise AM processes) and surface roughness. Both steps are performed automatically (or manually when needed) by the algorithm created based on principles of particle swarm optimization (PSO) algorithm using Visual C#.

Experimental tests show that the segmentation design improves AM processes from the aspects of building time, material consumption and the surface quality. Segmentation design empowers users of AM technologies to reduce consumption of material by decreasing the support structures, to decrease the time of building by lowering the segments height and to decrease the surface roughness.

This paper presents an original approach in efficiency improvement of AM technologies, thus bringing the AM one step closer to maturity.

The purpose of this paper is to propose a methodology to estimate manufacturing complexity for both machining and layered manufacturing. The goal is to take into account manufacturing constraints at design stage in order to realize tools (dies and molds) by a combination of a subtractive process (high‐speed machining) and an additive process (selective laser sintering).

Manufacturability indexes are defined and calculated from the tool computer‐aided design (CAD) model, according to geometric, material and specification information. The indexes are divided into two categories: global and local. For local indexes, a decomposition of the tool CAD model is used, based on an octree decomposition algorithm and a map of manufacturing complexity is obtained.

The manufacturability indexes values provide a well‐detailed view of which areas of the tool may advantageously be machined or manufactured by an additive process.

Nowadays, layered manufacturing processes are coming to maturity, but there is still no way to compare these new processes with traditional ones (like machining) at the early design stage. In this paper, a new methodology is proposed to combine additive and subtractive processes, for tooling design and manufacturing. A manufacturability analysis is based on an octree decomposition, with calculation of manufacturing complexity indexes from the tool CAD model.

This paper aims to provide a multi-objective optimization problem in design for manufacturing (DFM) approach for fused deposition modeling (FDM). This method considers the manufacturing criteria and constraints during the design by selecting the best manufacturing parameters to guide the designer and manufacturer in fabrication with FDM.

Topological optimization and bi-objective optimization problems are suggested to complete the DFM approach for design for additive manufacturing (DFAM) to define a product. Topological optimization allows the shape improvement of the product through a material distribution for weight gain based on the desired mechanical behavior. The bi-objective optimization problem plays an important role to evaluate the manufacturability by quantification and optimization of the manufacturing criteria and constraint simultaneously. Actually, it optimizes the production time, required material regarding surface quality and mechanical properties of the product because of two significant parameters as layer thickness and part orientation.

A comprehensive analysis of the existing DFAM approaches illustrates that these approaches are not developed sufficiently in terms of manufacturability evaluation in quantification and optimization levels. There is no approach that investigates the AM criteria and constraints simultaneously. It is necessary to provide a decision-making tool for the designers and manufacturers to lead to better design and manufacturing regarding the different AM characteristics.

To assess the efficiency of this approach, a wheel spindle is considered as a case study which shows how this method is capable to find the best design and manufacturing solutions.

A multi-criteria decision-making approach as the main contribution is developed to analyze FDM technology and its attributes, criteria and drawbacks. It completes the DFAM approach for FDM through a bi-objective optimization problem which deals with finding the best manufacturing parameters by optimizing production time and material mass because of the product mechanical properties and surface roughness.