Kwon, S., Oh, Y., Rosen, D. W., & Kim, S. (2025). Part consolidation and decomposition in redesign for additive manufacturing (RfAM): A taxonomy and review. Additive Manufacturing, 114, 105044. https://doi.org/10.1016/j.addma.2025.105044
Abstract:
This paper defines Redesign for Additive Manufacturing (RfAM) as a subset of Design for AM (DfAM), specifically focusing on altering an original design into a different form for production using AM technology. The authors categorize RfAM approaches based on changes in part count after redesign: Part Consolidation (PC) reduces the number of parts, Part Decomposition (PD) increases the number of parts, and Part Modification (PM) maintains the original part count. WhilePMhas been extensively reviewed in existing literature, this study specifically focuses on the relatively less explored areas of PC and PD, analyzing 126 papers (56 for PC, 70 for PD). This research classifies these approaches across four common objectives: cost, quality, manufacturability, and sustainability. The study identifies seven primary objectives for PC (including lightweighting and modularization) and six for PD (including printability improvement and support structure minimization). Furthermore, this paper proposes a novel taxonomy for combinations of the three RfAM approaches (PC, PD, and PM), categorizing them as either sequential or integrated strategies. Finally, future research directions and opportunities are presented from multiple perspectives, including the development of integrated RfAM frameworks, automated shape optimization, adaptive process parameter consideration, and sustainability-oriented methodologies. This comprehensive taxonomy provides valuable guidance for leveraging AM’s capabilities through strategic redesign approaches.
License type:
Publisher Copyright
Funding Info:
This research / project is supported by the A*STAR - Manufacturing, Trade, and Connectivity Programmatic Fund
Grant Reference no. : M24N3b0028