A new study from the University of West Attica argues that the full potential of additive manufacturing will remain unrealized until designers rethink how products are conceived for 3D printing. Published in Advanced Manufacturing, the research introduces a comprehensive design framework that encourages engineers to move beyond the geometry-driven rules that have dominated the field for more than a decade.
Although additive manufacturing has evolved into a robust production solution for aerospace, medical devices, automotive components, and specialized tooling, many digital design practices still mirror those used for traditional machining and fabrication. According to the research team, this legacy mindset restricts what 3D printing can accomplish.
The authors propose what they describe as a holistic, system-level approach to Design for Additive Manufacturing. Their framework ties together design intent, material behavior, build orientation, process parameters, sustainability considerations, and real-world performance. The goal is to align digital modeling more closely with how additive manufacturing systems behave during printing and throughout the product lifecycle.
“Design for Additive Manufacturing should not merely ensure printability,” says lead author Dr. Alexandros Kantaros. “It must connect material-process interactions, build orientation, tolerancing, and sustainability considerations to create designs that are innovative, reliable, and efficient.”
This perspective challenges the field’s prevailing focus on geometry optimization. Traditional DfAM guidelines tend to revolve around rules for overhangs, support structures, and lightweighting, yet they often fail to account for thermal distortions, anisotropic mechanical properties, or emissions-related environmental impacts. The research emphasizes that these factors become increasingly important as companies adopt additive manufacturing for full-scale production rather than prototyping.
A visual overview of the research team’s proposed workflow, showing how modern DfAM integrates process awareness, material behavior, and sustainability into the digital design stage. (Photo Credit: Antreas Kantaros / University of West Attica)
To address these gaps, the authors call for digital design environments that integrate simulation, AI-assisted manufacturability tools, and closed-loop optimization. Such platforms would help engineers anticipate deformation, choose appropriate material strategies, and understand how sustainability goals translate into design decisions. They argue that advanced workflows can unlock more ambitious applications, such as functionally graded materials, mass customization, and multi-part consolidation.
Co-author Professor Theodore Ganetsos notes that innovation will accelerate once design and manufacturing are no longer treated as disconnected stages. “By merging these perspectives, we can achieve sustainable, high-performance engineering solutions,” he says. The team highlights the growing need for interdisciplinary collaboration that includes engineering, materials science, industrial design, and environmental analysis.
The publication arrives at a moment when companies and researchers worldwide are pushing for more efficient and intelligent additive manufacturing systems. By emphasizing holistic thinking rather than rule-based design shortcuts, the University of West Attica team positions DfAM as a strategic enabler of sustainable industrial transformation.
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*Cover Photo Credit: University of West Attica