Dual design for additive manufacturing in engineering design: a systematic literature review

Purpose Dual design for additive manufacturing (DfAM) takes into account both the opportunities and constraints of AM simultaneously, which research shows is more effective than considering them separately. Unlike existing reviews, this paper aims to map DfAM research within the engineering design process, focusing solely on studies adopting dual DfAM. Additionally, it aims to suggest future research directions by analysing prominent research themes and their inter-relationships. Special emphasis is on theme inter-relationships concerning the conceptual, embodiment and detail design phases. Design/methodology/approach The study is based on a systematic literature review of 148 publications from January 2000 to February 2024. After screening, prominent research themes were identified and systematically analysed. Theme inter-relationships were explored using quantitative analysis and chord diagrams. Findings The findings reveal that studies either span the entire design process, the early design phases or the later design phases. Most research focuses on the later design phases, particularly within themes of design optimisation, design evaluation and AM-specific manufacturing constraints. The most frequent theme inter-relationship occurs between design optimisation and AM-specific manufacturing constraints. Overall, the findings suggest future research directions to advance dual DfAM research, such as development of design rules and guidelines for cellular structures. Originality/value This review proposes a model by mapping prominent themes of dual DfAM research in relation to the engineering design process. Another original contribution lies in analysing theme inter-relationships and visualising them using chord diagrams – a novel approach that did not exist before.