The influence of additive manufacturing on product design practice

Drawing on interviews with 13 professional designers who use Additive Manufacturing (AM) to develop and produce end-use products, this study examines AM’s influence on product design practice across its processes, tools, outcomes, stakeholder relationships, and sustainability considerations. Using Thematic Analysis and a systematic, iterative approach drawn from Constructivist Grounded Theory, five key core categories were identified: the hybridisation of digital and analogue design methods; computational and algorithm-led design; eclecticism in adopting virtual design tools; the importance of analogue design; a reduced distance with stakeholders and the awareness and importance of sustainability. The findings contribute to the theoretical debates on the evolution of product design by offering a model for how AM is reshaping contemporary design practice. This study offers practical insights for practitioners, educators, and organisations involved in implementing AM in product development workflows and defining the skills required to harness AM capabilities.