Design for Additive Manufacturing Method for a Mechanical System Downsizing

In this article, a new approach is presented to realize a multifunctional optimization of a mechanical system (MS). A methodology is first proposed in order to improve a product by using the AM opportunity. Then, to quantify the improvements of an optimized system, a new design indicator appointed “functional improvement rate” is defined. Finally, a case study, applied to a compressed-air Wobbler engine, is presented to demonstrate the relevance of the methodology and the functional improvement rate. The design adapted to traditional manufacturing is compared to a part-by-part optimized design and a multifunctional optimized design, both adapted to additive manufacturing.