Table 6 DfAM strategies regarding material and mechanical properties

Define the material requirements of the part based on its application and functionality

Consider the limited range of existing materials (polymeric materials): ABS, PLA, PC, PP, PPSF/PPSU, Nylon, ASA, elastomers and wax

Consider the mechanical properties of existing AM materials (Table 5)

Consider an experimental assessment of the mechanical properties of the unprocessed material

Consider the use of multi-material AM systems if necessary

Consider the effect of process parameters on the mechanical properties, weight, and inertia of the part, Eqs. (3) and (4)

Use high infill percentage values (low air gap values) and alternating filling patterns for high mechanical strength parts (e.g., functional parts under mechanical loads)

Use low infill percentage values (high air gap values) and open filling patterns for visual, light weight, low inertia, or low mechanical strength parts

Use small layer thickness values for high mechanical strength parts (e.g., functional parts under mechanical loads)

Consider anisotropic mechanical properties of the part according to the filling strategy, part orientation and layer orientation

Consider fully dense parts, and spiral, curved and alternating infill patterns to reduce the anisotropic effect

Consider the use of structures at different scales (micro, meso and macro structures), such as handles, ribs, cellular and lattice, to achieve the desired mechanical properties and optimise the part design

Align the infill pattern and layer according to the principal direction of the mechanical load in the part

Reduce layer thickness and build orientation, and increase air gap and raster angle to increase the wear resistance of the part [81]

Consider an experimental assessment of the mechanical properties of the part after its fabrication