Capabilities

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

  1. 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.

  2. 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.

  3. 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.

  4. 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.

  5. 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

    Product teams use large format assemblies models to move from screen-based design reviews to physical evidence for form, fit, appearance, or early function. D2M supports UAE and Saudi developers with additive manufacturing, scanning, and model-making routes using routes such as Scanology KSCAN-E and Scanology KSCAN-MAGIC matched to the decision the prototype must support.

  • Lightweight Brackets & Structural Components

    Lightweight brackets and structural components are common additive manufacturing candidates when mass reduction, complex geometry, or assembly consolidation matter. D2M helps teams review part requirements, material route, inspection needs, and approval boundaries before choosing how to manufacture them.

  • High-Strength Brackets & Structural Components

    Engineering teams consider high strength brackets when conventional machining or tooling limits geometry, cooling, weight, or low-volume economics. D2M helps Middle East teams review metal additive manufacturing using routes such as XACT Metal XM200G with material, machining, and inspection requirements in view.

  • Complex Internal Channel Parts

    Engineering teams consider complex internal channel when conventional machining or tooling limits geometry, cooling, weight, or low-volume economics. D2M helps Middle East teams review metal additive manufacturing using routes such as XACT Metal XM200G with material, machining, and inspection requirements in view.

  • Metal Lattice Structures

    Metal lattice structures are considered when teams need lightweighting, controlled stiffness, surface area, or complex internal geometry. D2M helps review LPBF design constraints, alloy choice, post-processing, and inspection routes for lattice-based components.

  • Thermal Management Components

    Engineering teams consider thermal management when conventional machining or tooling limits geometry, cooling, weight, or low-volume economics. D2M helps GCC teams review metal additive manufacturing using routes such as XACT Metal XM200G with material, machining, and inspection requirements in view.

  • Precision Fluidic Devices & Manifolds

    Engineering teams consider precision fluidic devices when conventional machining or tooling limits geometry, cooling, weight, or low-volume economics. D2M helps GCC teams review metal additive manufacturing using routes such as Stratasys Origin® Two with material, machining, and inspection requirements in view.

  • Snap-Fit & Functional Mechanical Components

    Snap-fit and functional mechanical components need careful review of material behavior, tolerances, wear, assembly force, and mating geometry. D2M helps teams assess additive manufacturing and prototype routes before moving these parts into functional trials.

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 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.

Related case studies

Plan the next step

Discuss the application, qualification requirements and ownership model before defining the implementation route.

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