Additive manufacturing (AM), commonly known as 3D printing, has played a significant role in the success of Industry 4.0 by enabling rapid prototyping, tooling, and production. AM uses a layer-by-layer building process from CAD models, providing greater design flexibility for creating intricate and customized components. However, there is a prevailing misconception that design complexity comes at no additional cost for AM. This notion is challenged, especially when AM intricate components with complex external surfaces can lead to longer build times and increased costs. This article introduces a method for quantifying design complexity in additively manufactured parts using a mixed-methods approach. This approach leverages qualitative and quantitative data to assess the additive manufacturing complexity index (AMCI) of parts. The AMCI is a metric developed to measure and evaluate the complexity of parts produced using AM processes, considering factors such as geometry, features, AM machine settings, and parameter requirements. The technique aims to assist manufacturers and designers in early-stage part development by quantifying the difficulty of building parts using VAT photopolymerization (VPP) AM technology, enabling informed decision making. The article also discusses the concept of design complexity in AM. In addition, the article presents case studies and data analysis to test the proposed method. The analysis reveals that various factors such as geometry, features, AM machine settings, and parameter requirements can impact the manufacturability of parts in VPP AM processes.
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