Redesigning Traditional Mechanical Components for Additive Manufacturing

Purpose: The study attempts to re- design classical parts such as brackets, gears and springs, from basic principles which design based on Additive Manufacturing (AM)design, focusing on the mechanical meta- materials and topology optimization. They aim to create lighter, stronger and more sustainable automotive products to stay in line with Industry 4.0 standards. Methodology: A four-stage research approach was used. A comprehensive literature review was conducted to provide the theoretical basis. Second, expert interviews of professional developers yielded insights into real-world design problems. The third task was to perform computer analysis of the selected components via the analysis of topology optimization and Finite Element Analysis (FEA). Last, the prototypes were made with Fused Depositing Modeling (FDM) and Selective Laser Melting (SLM), while the effectiveness of the simulation was also examined. Findings: 100 weight savings were achieved and stiffness was not compromised 35–60%. Introducing auxetic and pentamode metamaterials improved energy dissipation and resistance to fatigue. Experiments showed that the simulations were accurate, and experts using expert opinions validated the industrial applicability of the designs. Unique Contribution to Theory, Practice and Policy: We verify an established framework that bridges the gap between theory-based design and real-world prototyping. It adds value to the field of engineering by providing a model of systematic rewriting that is appropriate for high-tech and low-tech contexts alike. The results also offer policy implications for sustainable and intelligent manufacturing, especially in developing countries.