Toward a holistic approach to design for additive manufacturing: Rethinking how we design for 3D printing

Researchers from the University of West Attica have introduced a comprehensive framework that redefines how products are designed for additive manufacturing (3D printing). Published in Advanced Manufacturing, the study emphasizes a system-level, process-aware approach that integrates design intent, material behavior, and sustainability—moving beyond geometry-focused rules to unlock the full potential of additive manufacturing.

Additive Manufacturing (AM), commonly known as 3D printing, has matured from a rapid prototyping tool into a fully capable production technology used in aerospace, healthcare, and automotive industries. Yet, many design practices still follow principles developed for traditional, subtractive manufacturing methods.

Addressing this gap, the research team at the University of West Attica present a new perspective titled “Toward a Holistic Approach for Design for Additive Manufacturing: A Perspective on Challenges, Practical Insights, and Research Needs,” published in Advanced Manufacturing. The paper proposes a system-level and process-aware design mindset—one that aligns digital design tools with the physical realities of AM processes.

“Design for Additive Manufacturing should not merely ensure printability,” explains Dr. Kantaros. “It must connect material-process interactions, build orientation, tolerancing, and sustainability considerations to create designs that are innovative, reliable, and efficient.”

The study critiques existing DfAM methods that focus mainly on geometry optimization, arguing that such heuristics overlook critical factors such as anisotropy, thermal distortions, and lifecycle sustainability. Instead, the authors advocate for an integrated workflow that combines simulation, optimization, and AI-assisted manufacturability feedback within digital design environments.

Strategic applications such as part consolidation, mass customization, and functionally graded materials demonstrate how holistic DfAM thinking can improve product performance while reducing environmental impact and production costs.

“True innovation in additive manufacturing begins when design and manufacturing are no longer treated as separate stages,” adds co-author Professor Theodore Ganetsos. “By merging these perspectives, we can achieve sustainable, high-performance engineering solutions.”

This publication contributes to the growing movement to make DfAM education and practice more interdisciplinary—linking engineering, materials science, and industrial design—and positions additive manufacturing as a catalyst for sustainable, intelligent production systems.

Paper information: Kantaros, A.; Ganetsos, T.; Pallis, E.; Papoutsidakis, M. “Toward a Holistic Approach for Design for Additive Manufacturing: A Perspective on Challenges, Practical Insights, and Research Needs.” Advanced Manufacturing, 2025. DOI: https://doi.org/10.55092/am20250011