A comprehensive design framework for additive manufacturing in the automotive industry: a case study
Authors: Lkadi O. , Abouhazim S. , Nassraoui M. , Bouksour O. 
Published: April 2024

The work aims to propose a comprehensive design framework for additive manufacturing and apply it to a case study of the height adjuster handle of a car. The aim is to provide designers and engineers with a practical example of how the framework can be used to design a complex part for additive manufacturing. The article also aims to demonstrate the potential benefits of additive manufacturing in the automotive industry, such as improved performance, reduced times, and cost savings. Additionally, the article aims to compare the developed framework with existing design for additive manufacturing (DFAM) methodologies and highlight its unique features and advantages in designing the height adjuster handle.The study used qualitative and quantitative data collection and analysis methods. The first phase of the study involved a systematic review of existing DfAM methodologies and a critical analysis of their strengths and weaknesses. Based on this analysis, a new DfAM framework is developed, which aims to address the limitations of existing frameworks and provide a comprehensive design approach for additive manufacturing. The second phase of the study involved applying the developed framework to a case study of a complex automotive part - a height adjuster handle. The design requirements of the height adjuster handle were identified based on the principles of DfAM, and the part was designed using computer-aided design (CAD) software and optimised topologically using ANSYS software. In the third phase, the performance of the height adjuster handle designed using the developed framework was compared with a part manufactured with injection moulding technology. The comparison was based on various performance criteria, including mechanical properties, dimensional accuracy, and production time and cost.The findings of the study demonstrate the effectiveness of the developed design framework for additive manufacturing (DfAM) in producing a complex automotive part with improved performance characteristics and reduced lead time.Although the results of the study provide important insights into the effectiveness of the developed DfAM framework for producing a complex automotive part, there are some limitations to the research that should be considered, such as the case study involved the design of a single part, and the results may not be generalisable to other parts or applications. Further research is needed to validate the effectiveness of the DfAM framework for a broader range of automotive parts.The findings of the study have important practical implications for the automotive industry. The developed DfAM framework can be used in the FDM technology. It can be used as a decision aid in the manufacturing of FDM parts in order to improve the efficiency and cost-effectiveness of the production process for complex automotive parts.The value of the study is the development of a novel DfAM framework and the demonstration of its effectiveness in a case study. The proposed framework can be used as a reference for future research. It can also provide practical guidance for industry professionals seeking to improve the efficiency and cost-effectiveness of their additive manufacturing processes.