DfAM in Action: How Design Optimization Saves Weight and Cost
In metal additive manufacturing, Design for Additive Manufacturing (DfAM) isn’t a buzzword—it’s a powerful discipline that unlocks performance, accelerates lead times, and drives down costs. At Howco Additive, we apply DfAM across industries to transform the way parts are engineered and delivered.
This article breaks down how DfAM creates real-world value across five core categories: weight reduction, part consolidation, performance optimization, cost and lead time savings, and sustainability.
1. Weight Reduction: Eliminate What You Don’t Need
Reducing weight without sacrificing performance is one of the biggest wins in aerospace, energy, and motorsports.
How DfAM achieves it:
Lattice structures: Replace solid volumes with lightweight infill geometries that maintain structural stiffness.
Topology optimization: Use FEA-driven tools to remove non-load-bearing material.
Shell-and-core strategies: Print hollow sections with reinforced ribs for strength where it counts.
In one aerospace bracket project, we reduced part mass by 42% while maintaining mechanical integrity through lattice infill and filleted stress concentrators.
2. Part Consolidation: Fewer Parts, Fewer Problems
DfAM allows us to redesign assemblies that used to require multiple components into monolithic parts—improving reliability and eliminating interfaces.
Benefits:
No bolted or welded joints
Eliminate leak paths in hydraulic or fluid systems
Streamlined assembly and fewer quality control points
Example: A downhole flow component previously assembled from 4 parts was redesigned and printed as a single unit—cutting assembly time from hours to minutes and eliminating 3 potential failure points.
3. Performance Optimization: Make It Work Harder
DfAM enables us to enhance functionality in ways that are simply not possible with conventional machining.
Examples include:
Internal cooling and flow channels: Optimize thermal regulation and reduce pressure drops
Graded wall thickness: Thicker where needed for load, thinner where not
Directional reinforcement: Align features with stress paths
In turbine nozzle segments, conformal internal channels helped increase cooling efficiency by over 30% compared to traditional drilled passages.
4. Cost and Lead Time Savings: Print What You Need, When You Need It
Yes, DfAM can save money—but it’s not just about printing cheap. It’s about smarter allocation of time, labor, and material.
DfAM reduces:
Material waste: Net-shape parts minimize buy-to-fly ratios
Machining time: Near-net shapes reduce CNC hours
Inventory costs: Digital inventory replaces physical shelves
A complex Inconel 718 bracket that used to require 4 setups and 60+ hours of machining was redesigned for AM with just 1 finishing pass—saving over $1,500 per unit and shaving weeks off the lead time.
5. Sustainability: Better Parts with a Smaller Footprint
DfAM contributes directly to environmental goals by improving material efficiency and supply chain resilience.
Environmental advantages:
Less waste: AM consumes only the powder that is melted—excess is reused
Lower transport impact: Print locally, reduce international freight
Fewer secondary processes: Less energy-intensive rework and scrap
A major energy OEM cut CO₂ emissions from logistics by 60% by switching from castings shipped overseas to AM parts produced domestically with digital part files.
Conclusion: DfAM Is the Catalyst for AM’s True Potential
Design for Additive Manufacturing is the key to unlocking everything AM promises: weight savings, faster delivery, improved performance, and smarter cost structures.
At Howco Additive, we bring DfAM to the forefront of every project. Whether you're starting with a legacy design or a clean sheet, our engineering team partners with you to reimagine what’s possible—and then make it real.