Preface vii Acknowledgments ix List of Abbreviations xi 1 Introduction 1 1.1 Additive Manufacturing 1 1.2 Design for Additive Manufacturing (DfAM) 7 1.3 Challenges and Future Directions of DfAM 9 References 11 2 Engineering Design Process 15 2.1 Design Function Analysis 16 2.2 Concept Generation 17 2.3 Geometric Modeling 18 2.4 Detailed Design 19 2.

5 Computational Design 20 2.6 Bridging the Gap: From Traditional Design to Design for Additive Manufacturing 22 References 23 3 Design Conceptualization with Additive Manufacturing 25 3.1 Introduction 25 3.2 DfAM Worksheet 26 3.3 Design Heuristics for AM 28 3.4 Integrated DfAM Method 30 3.5 Automated AM Candidacy Prediction Tools 34 3.6 Multifunctional Bio-inspired Design Method 40 3.

7 Summary 40 References 41 4 Part Consolidation and Assembly Design 45 4.1 What Is Part Consolidation? 45 4.2 Literature Review 48 4.3 The Holistic Part Consolidation Design Workflow 52 4.4 Part Candidate Selection 54 4.5 Fusion of Parts 66 4.6 Emerging Trends in Part Consolidation and Assemblies 80 4.7 Summary 84 References 84 5 Manufacturing Constraints and Design Guides for Additive Manufacturing 89 5.

1 General Constraints and Guidelines for AM 90 5.2 Design Guidelines for Polymeric AM Process 96 5.3 Design Guidelines for Metal AM Process 105 5.4 Design Guidelines for Other AM Processes 110 5.5 Conclusions 113 References 114 6 Topology Optimization, Structural Optimization, and Multifunctional Optimization 117 6.1 Basic Concepts of Engineering Optimization 117 6.2 Structural and Topology Optimization for AM 122 6.3 Multi-disciplinary Design Optimization for AM 128 6.

4 Reliability-based Design Optimization 130 6.5 Conclusion 131 References 131 7 Lattice Structure Design and Simulation 133 7.1 Introduction to Lattice Structures 133 7.2 Design Methodology for Lattice Structures 136 7.3 Numerical Simulation of Lattice Structures 141 7.4 Lattice Structure Optimization Approaches 145 7.5 Design Cases of Lattice Structures 149 7.6 Bio-inspired Lattice Design 153 7.

7 Conclusion 154 References 154 8 Advanced Topics in DfAM: Digital Materials and Emerging Paradigms 157 8.1 Introduction to Digital Materials 157 8.2 Fabrication of Digital Materials 158 8.3 Multi-materials Design 161 8.4 Voxel Printing Design 164 8.5 Fiber-reinforced Composite Design 165 8.6 Summary 167 References 167 9 Data-driven and Machine Learning-based Design for Additive Manufacturing 171 9.1 Foundations of Data-driven and ML-based DfAM 172 9.

2 ML Across DfAM Workflow 173 9.3 Cross-cutting Strategies and Future Directions 176 References 178 Index 179.