A novel methodological framework for design for additive manufacturing for sheet metal tooling

• DOI: 10.1007/s40964-025-00990-0
• Publication Date: 2025-02-07T14:31:13Z
• Authors: Sagil James; Brian Buddine

Abstract Additive manufacturing (AM) has the ability to benefit sheet metal manufacturing industries by implementing novel design solutions for tools and dies. However, there is a lack of support for the use of additive manufacturing in sheet metal manufacturing. Unfortunately, designers do not have proficient guidance for incorporating these innovative strategies. Existing Design for Additive Manufacturing (DFAM) approaches are precisely reviewed in this paper. They are then analyzed further by being related to conventional sheet metal manufacturing processes. However, existing DFAM guidelines do not provide a complete development process for design and manufacturing. Therefore, a novel methodological framework for DFAM of tools in sheet metal fabrication processes is proposed. Existing design strategies for sheet metal tooling through conventional manufacturing and additive manufacturing are utilized in the new DFAM modular framework. A case study example follows the DFAM framework to offer designers additional guidance through the design and manufacturing stages for sheet metal tooling with the use of additive manufacturing as a secondary process.