Additive manufacturing technologies allows to get rid of pre-existing manufacturing restrictions that previously have limited a designer’s ability to make the product they had in mind. With these processes, products can be highly customized to the user thus, potentially increasing their applications. As additive manufacturing technologies evolve, and more new materials become available the field of product design has the potential to greatly change.
In order to fully exploit the capabilities of these technologies the application of the term “design freedom” for weight reduction as well as functional optimizations takes up a key role. FEM tools such as Altair Inspire provide the possibility to design parts, purely based on boundary conditions taking full advantage of the possibilities provided by additive manufacturing.
The presentation will show the application of such a numerically supported part design covering the complete process chain from idea to a “ready to fly” product. The potential of weight savings and lead time reduction as well as future needs in order to close existing gaps in the design process are addressed.