Design Optimization

Engineering for Performance and Efficiency

Unlock the full potential of additive manufacturing with advanced design strategies tailored to your specific application and production goals. Our team combines deep engineering expertise with state-of-the-art tools to optimize every stage of the digital workflow — from initial concept to build-ready file.

A person wearing glasses works at a desk, using a computer with a large monitor displaying a 3D CAD model of a circular mechanical component. A small decorative reindeer figure is beside the keyboard.

Design for Additive

Designing for AM isn’t just about shape — it’s about function, manufacturability, and efficiency. We help you create geometries that take full advantage of AM’s unique capabilities:

  • Self-supporting features:

    Reduce or eliminate the need for support structures through smart geometric choices

  • Lattice and TPMS structures:

    Optimize weight and performance with complex internal architectures

  • CAD-based adaptations:

    Adjust existing designs to make them AM-compatible while preserving intent

  • Topology optimization:

    Generate high-performance geometries based on real-world load and boundary conditions

Support Structure Optimization

Support strategies are critical to successful builds. We engineer support solutions that balance mechanical stability with efficient post-processing:

  • Advanced support designs:

    Tailored to each material and geometry

  • Ease of removability:

    Reduce post-processing time and improve surface finish

  • Material and build time optimization:

    Minimize waste while maximizing print success

  • Topology optimization:

    Generate high-performance geometries based on real-world load and boundary conditions

Build Simulation

Before printing, we simulate the process to predict and correct issues — saving time and cost:

  • Mechanical and thermal simulation:

    Evaluate stresses, strains, and heat flow during printing

  • Deformation pre-compensation:

    Adjust geometry pre-build to counteract predicted distortions

  • Support structure optimisation:

    Virtually validate support strategies before production

  • Thermal heat stabilisation:

    Ensure consistent heat distribution to reduce internal stresses

Data Preparation

Our data preparation workflow ensures a reliable transition from design to production:

  • Build layout creation:

    Optimize part orientation and nesting for print efficiency

  • Parameter assignment & slicing:

    Apply process-specific print parameters for each geometry

  • Process optimization:

    Fine-tune strategies for surface quality, material usage, and cycle time

  • Topology optimization:

    Generate high-performance geometries based on real-world load and boundary conditions

Let us help you design smarter, print better, and deliver more!

Let’s explore how additive manufacturing can optimize your product – lighter, stronger, and more efficient. Book a consultation with our experts today.

If you want to know more, get in touch with us at info@amexci.com.