Reshaping the Product Development Process with Additive Manufacturing

To innovate quickly and create successful products, research, design, and engineering must occur simultaneously. Fifth-generation innovation replaces linear manufacturing with fluid and concurrent development.

Additive Manufacturing (AM) is a distinct method that allows detailed structures, unique features, and multiple materials to be constructed without tooling. Applying 3D printing alongside Design for Additive Manufacturing (DfAM) as the primary production method from the very beginning focuses every step of the ideation process. In this manner, a prototype containing the required research and design features while retaining the core idea can be treated as the final product. Based on this outlook and the unique capabilities of AM, every part of the development process happens simultaneously. This shift establishes a close collaborative triangle among the end user, the product designer, and the AM engineering team.

Two case studies support this reshaped process. The Scarce City project involves the ideation of unique transparent light vessels. By using AM as the core manufacturing method and applying DfAM rules alongside the collaborative triangle, early prototypes and print settings translate directly into the final manufacturability of the exhibit.

Likewise, the 3D printed tactile Braille book project places multimaterial AM and automated production for small customisable quantities at its core. This approach enables the creation of parts with highly tuned tactile ergonomics and allows for rapid adjustments to suit specific needs. With AM, what is built during the prototype phase can be brought directly to final production.

Using these two distinct applications, it becomes clear that allowing research, design, prototyping, and manufacturability to occur simultaneously while fully retaining the original design intention aligns perfectly with the fifth generation innovation process.