Redesign optimization for manufacturing using additive layer techniques

Abstract Improvements in additive manufacturing technologies have the potential to greatly provide value to designers that could also contribute towards improving the sustainability levels of products as well as the production of lightweight products. With these improvements, it is possible to eliminate the design restrictions previously faced by manufacturers. This study examines the principles of additive manufacturing, design guidelines, capabilities of the manufacturing processes and structural optimisation using topology optimisation. Furthermore, a redesign methodology is proposed and illustrated through a redesign case study of an existing bracket. The optimal design is selected using multi-criteria decision analysis method. The challenges for using additive manufacturing technologies are discussed.