Design for Additive Manufacturing (DfAM): Strategies and Best Practice

Unlock the full potential of AM with this hands-on CPD course. Learn how to optimise designs for lightweighting, part consolidation, and performance. Explore lattice structures, topology optimisation, and real-world case studies, with practical CAD sessions and live demonstrations included. 

Course Description

This CPD course equips industry professionals with the tools and techniques needed to design effectively for additive manufacturing (AM). Unlike traditional design methods, DfAM unlocks new possibilities for part consolidation, lightweighting, and enhanced performance. Through real-world case studies and hands-on guidance, participants will learn how to identify suitable applications, select the right materials and processes, and apply design strategies that maximise the advantages of AM while avoiding common pitfalls. The course also covers mechanical behaviour, testing, and post-processing to ensure designs are not only manufacturable but functional and reliable. 

Learning Outcomes: 

Understand the principles of Design for Additive Manufacturing (DfAM) and how they differ from traditional design approaches. 

Identify suitable parts for AM and apply design strategies such as topology optimisation and part consolidation, to optimise material efficiency, printability and functional requirements.  

Use CAD tools to implement DfAM principles, including generative design workflows, build orientation, and geometry preparation. 

Consider post-processing and quality assurance requirements to ensure that AM parts are functional, accurate, and ready for end-use or production. 

Course Outline: 

Morning 

Introduction to DfAM: principles and advantages over traditional design 

Down-selection: identifying parts best suited to AM 

Core design strategies: lattice structures, topology optimisation, part consolidation, material efficiency 

Case studies from aerospace, automotive and healthcare sectors etc. 

Live demonstration: optimisation and generative design walkthrough 

Afternoon 

Interactive CAD session: applying DfAM principles in practice 

Addressing anisotropy and mechanical behaviour in AM parts 

Post-processing considerations and quality assurance in ‘production-ready’ components