Design Optimization (DfAM)
DfAM support reviews component geometry, material route, manufacturability, documentation, and performance requirements before additive manufacturing is selected.
Systematic Design Optimization for Additive Production
Transitioning to additive manufacturing requires more than a direct conversion of existing CAD files. True value is realized when parts are fundamentally redesigned for the AM process. Our DfAM service moves beyond simple part replacement to unlock significant performance gains and economic advantages that are unattainable with conventional manufacturing methods.
Engineering for Measurable Outcomes
We focus on quantifiable improvements by applying core engineering principles to your components. This includes topology optimization to place material only where it is structurally necessary, the integration of complex lattice structures for lightweighting, and part consolidation to reduce assembly complexity, BOM size, and potential points of failure. Each design is optimized for a specific AM technology and material to ensure predictable quality and cost-effective production at scale.
Our Methodology
Initial Assessment & Requirements Definition
We analyze the component's functional requirements, load cases, operating environment, and business objectives. This phase establishes key performance indicators (KPIs) for the redesign project.
Iterative Optimization & Simulation
Using advanced generative design and simulation tools (FEA/CFD), our engineers create and analyze multiple design candidates. This data-driven process ensures the optimized geometry meets or exceeds all performance specifications.
Manufacturability & Process Validation
The design is refined for a specific AM process (e.g., DMLS, MJF), considering build orientation, support structures, and thermal management. This step guarantees a repeatable and high-quality production outcome.
Prototyping & Empirical Verification
We manage the fabrication of physical prototypes for dimensional inspection and functional testing. This validates simulation data and confirms the part performs as required under real-world conditions.
Technical Data Package Handoff
Upon final approval, we deliver a complete production-ready data package, including optimized CAD files, build preparation instructions, and quality assurance protocols for scalable manufacturing.
Related capability context
Application Opportunities
Large-Format Assemblies & Consolidated Multi-Part Designs
Large-Format Assemblies & Consolidated Multi-Part Designs should be assessed against fit, material route, inspection needs, operating conditions, and commercial value before a manufacturing process is selected.
Lightweight Brackets & Structural Components
Lightweight Brackets & Structural Components should be assessed against fit, material route, inspection needs, operating conditions, and commercial value before a manufacturing process is selected.
High-Strength Brackets & Structural Components
High-Strength Brackets & Structural Components should be assessed against fit, material route, inspection needs, operating conditions, and commercial value before a manufacturing process is selected.
Complex Internal Channel Parts
Complex Internal Channel Parts should be assessed against fit, material route, inspection needs, operating conditions, and commercial value before a manufacturing process is selected.
Metal Lattice Structures
Metal Lattice Structures should be assessed against fit, material route, inspection needs, operating conditions, and commercial value before a manufacturing process is selected.
Thermal Management Components
Thermal Management Components should be assessed against fit, material route, inspection needs, operating conditions, and commercial value before a manufacturing process is selected.
Precision Fluidic Devices & Manifolds
Precision Fluidic Devices & Manifolds should be assessed against fit, material route, inspection needs, operating conditions, and commercial value before a manufacturing process is selected.
Snap-Fit & Functional Mechanical Components
Snap-Fit & Functional Mechanical Components should be assessed against fit, material route, inspection needs, operating conditions, and commercial value before a manufacturing process is selected.
Relevant Industries
Aerospace
Aerospace teams work under strict traceability, material justification, and approval constraints before any manufacturing route can move beyond review. D2M supports application assessment, technology route selection, workflow design, documentation planning, and training for aerospace manufacturing and maintenance contexts.
Automotive
Automotive teams need disciplined routes for tooling, fixtures, prototypes, and low-volume components before additive manufacturing is used in production support. D2M supports application review, material selection, design preparation, documentation, and operator training for automotive manufacturing workflows.
Industrial Manufacturing
Industrial manufacturing teams need a disciplined way to review spares, tooling, fixtures, and production aids before moving them into controlled workflows. D2M supports part selection, workflow design, technology route selection, documentation, operator training, and staged implementation planning.
Medical (Non-Clinical)
Healthcare support teams need governed workflows for anatomical models, training aids, device development support, and documentation before manufacturing is used. D2M helps assess applications, define equipment and software workflows, plan quality documentation, and support training for healthcare manufacturing support contexts.
Energy
Energy operations involve demanding environments, asset downtime risk, inspection requirements, and material constraints that must be reviewed before production decisions. D2M supports candidate application review, material route assessment, workflow design, documentation, and training for energy-sector manufacturing support.
Technology Routes
FDM®
FDM is a polymer additive manufacturing process used for selected tooling, fixtures, prototypes, and end-use applications. D2M helps clients review material fit, workflow control, documentation, operator training, and implementation route.
P3™ DLP
P3 DLP is a photopolymer additive manufacturing process used for selected polymer applications where surface quality, material behavior, and repeatable workflow control matter. D2M helps clients assess fit before production use.
SAF™
SAF Selective Absorption Fusion is a polymer additive manufacturing process suited to selected higher-volume PA12 applications. D2M helps clients assess application demand, material route, inspection needs, documentation, and production workflow before recommending SAF.
Metal
Metal additive manufacturing can support selected industrial, aerospace, and defense-adjacent applications where the material route, qualification effort, inspection plan, and documentation requirements are clearly defined.
SLA
SLA stereolithography is a photopolymer additive manufacturing process used for precise models, tooling patterns, and visual or functional prototypes. D2M helps clients assess whether SLA fits the application, material route, accuracy requirement, and workflow.
Relevant Systems & Materials
NX CAD for Additive Manufacturing
NX CAD for Product Engineering
Simcenter
Scanology NimbleTrack GEN2
Scanology KSCAN-X
Scanology TrackProbe
Related Case Studies
General Atomics Aerospace Additive Manufacturing Case Study
Review how GA-ASI structured additive manufacturing around an AM ecosystem, business cases, FDM production workflows and qualified partners.
Lockheed Martin Antero 840CN03 FDM Aerospace Parts Case Study
Review how Lockheed Martin Space evaluated FDM additive manufacturing and Antero 840CN03 for repeatable Orion spacecraft parts with ESD requirements.