How does designing for current manufacturing methods differ from designing for additive manufacturing (DFM vs. DFAM)?
Most of us have spent the majority of our careers learning DFM, and it has been critical to reaching the current state of part and product quality, and reliability. DFAM, however, adds a whole new range of design freedom. Your parts and products can now have a high degree of complexity at no cost penalty.
With AM, multiple parts can often be merged into one printable part that eliminates the tolerances and cost required to make three (or 4 or more) different parts and assemble them.
*like this crosshatch pattern which reduces weight and material needed, and in some cases, improves physical properties.
Along the same lines, multiple parts can be designed as one assembly with the clearance built into the joints. Once the parts have had the support material removed (if needed, depends on design) they become mechanisms.
AM also allows for a wide range of infill* inside a part which can significantly reduce the weight and amount of material needed per part without compromising strength.
AM introduces a whole new range of design capabilities; the more you use it the more it benefits your products.