Parts consolidation: Mechanical assemblies are common in industrial products. In complex mechanical machines, there are more than tens, hundreds, or even thousands of components that are either welded, or bolted, or press‐fit to each other. Parts consolidation offers many advantages due to the reduction of the number of individual parts needed to be designed, manufactured, and assembled to form the final system. Part consolidations offer multiple benefits: (i) design simplification; (ii) reduction of overall project costs; (iii) reduction of material loss; (iv) reduction of weight; (v) reduction of overall risk where the number of risks associated with too many suppliers of individual parts drops; (vi) better overall performance, as it enables geometries that are desirable but cannot be made with conventional manufacturing.

       Functionally graded materials (FGMs) and structures (FGSs): The integration of multiple advanced materials into one component is one of the most rapidly developing areas of AM technology. The capability to create multiphase materials with gradual variations in compositions is one of the important features of AM. During the layer‐by‐layer step of AM processes, the material composition can gradually be altered to obtain the desired functionality. AM also enables the development of FGSs with a single‐phase material, where the density is gradually changed through the addition of cellular/lattice structures; and embedding objects (e.g. sensors) within structures. Among AM processes, DED is the most promising technology to develop such structures, where different powders can be switched insitu to develop desired composition and alloys. Figure 1.6 shows different FGMs that can effectively be developed by DED. Figure 1.7 shows a cutting tool with an embedded fiber optic, as an FGS, developed by an AM‐based process.

       Parts with conformal cooling channels for increased productivity: Cooling systems play a vital role in the productivity and performance of many parts. For example, in an injection molding process, the cooling period of a production cycle counts for more than 40% of cycle time. If this period drops by means of taking the heat out of the mold, the productivity increases dramatically. In an active antenna, developing conformal channels will be very important as the generated heat can be dissipated from the zone much effectively, not to affect the antenna performance. With AM, designers can have much more freedom to incorporate conformal cooling channels into their designs that facilitates uniform cooling over the entire surface. Sub‐conformal channels can be included in the optimization process. Figure 1.8 shows a design of an insert used in molds. The design includes a conformal cooling channel wherein the support cells are used to enhance the heat transfer.

       Parts repair and refurbishment: Machining errors or last‐minute engineering changes can affect on‐time delivery of tooling and potentially impact the introduction date of a new product. AM, especially DED processes, can be applied as a safe technology to repair tooling, especially on critical contacting surfaces. AM increases tool life and, in many cases, can save a high‐value tool that would otherwise need to be replaced. Figure 1.9 shows an LDED process used in the in‐situ repair of turbine blades.