Abstract
Additive Manufacturing (AM) offers great flexibility in producing parts and products that are geometrically complex. Therefore, several design methods have been developed aiming to exploit the AM capabilities and advantages over conventional manufacturing. However, it is crucial to further investigate the potential of AM to enable substitution of established manufacturing processes used in the production of structural components. In this study, a design framework for AM is presented, focusing on replacing conventionally manufactured structural components, operating under load conditions with re-designed ones, capable of exploiting AM process advantages. The proposed framework is validated by a case study dealing with the redesign of a formula-style race car's structural component. Topology optimization and FE Analysis are implemented in order to redesign a suspension component and predict the structural integrity of the new component. Finally, the freedom of design and the manufacturing capabilities of AM in manufacturing sectors demanding low weight and high stiffness characteristics of components are further outlined and more applications of the suggested design framework are described.
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