In modular products conflicting objectives may occur. This leads to characteristics as component-dependent oversizing and undersizing as well as increased complexity of the interfaces. These conflicts can be resolved using the potentials of AM processes. For the best use possible, the potentials are systematically considered in the early design phases as part of an extended procedure. The extended procedure improves the benefit-effort ratio of modular respectively individual products and a further optimization of the product architecture and consideration of synergy effects is achieved.

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Additive manufacturing enables new possibilities for the design of end products. These are rooted in the potentials of the manufacturing technology, such as flexible, tool-free production. These potentials can be used for the economic and flexible production of customized products. To support the use of the potentials, a development method was created which identifies optimization areas within a product. Therefore, the complexity is reduced by using of product functions. Characteristic functions and structural configurations are used to identify optimization areas. This contribution describes the application of the new development method to an existing mechanical transtibial prosthesis. In doing so optimization areas are identified which may make use of the potentials provided by additive manufacturing. One area is the interface between the prosthesis and the ground. By analyzing walking environments and the gait cycle the need for walking assistance on deformable surfaces was identified. Significant improvements were achieved through a functional integrated, additive manufactured foot sleeve.

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