A case study on the part optimization using eco-design for additive manufacturing based on energy performance assessment

Additive manufacturing (AM) is seen as a promising technology to improve the resource efficiency and environmental performance in manufacturing systems. However, recent studies have shown that the ecological advantages of AM are dependent on the design of the manufactured parts. This leads to the requirement of the implementation of eco-design for AM (Eco-DfAM). Therefore, this paper presents a case study in which an industrial part has been analyzed and optimized using the energy performance assessment (EPA)-based Eco-DfAM method. In the first step of the case study, generative design has been applied and different design solutions with varied lightweighting factors were proposed. The energy consumption of each design solution is then quantified using a simulation method. Based on the defined energy performance indicators, the energy performances of different solutions are evaluated and compared. Finally, the optimized part with the best evaluation result is produced using the selective laser melting (SLM) process. The results of this case study provide valuable experience for designers who are facing decision-making issues in Eco-DfAM.