From Redesign to Additive Manufacturing: Approaches and Case Study in Automotive

Additive manufacturing technologies enable the realization of complex and free-form geometries that are difficult or impossible to realize with traditional subtractive processes. The development and widespread use of algorithmic optimization methods, including topology and shape optimization, lattice structures, and generative design, accelerate this manufacturing revolution. The redesign of existing parts is a common practice to improve the overall performance of mechanical systems. The practice of designing additive manufacturing components, known as Design for Additive Manufacturing, enables designers to enhance functionality, reduce the number of parts, and minimize the overall weight, thereby obtaining an optimized shape for the analyzed item. This paper proposes a method to support designers in applying optimization techniques for mechanical components. The paper also applies the proposed approach to redesign an automotive suspension arm for a C-segment passenger car. The case study begins with the analysis of a reference part produced using conventional manufacturing and ends with the proposal of a new geometry to be realized by metal 3D printing.