Design for Additive Manufacturing (DfAM), is a one of the most commonly used and foundational techniques used in the development of new products, and particularly those that involve largescale metallic structures composed of hollow components. One such AM technique is Wire Arc Additive Manufacturing (WAAM), which is the application of robotic welding technology applied to Additive Manufacturing. Due to the lack of a simple method to describe the fabricating constraint of WAAM and the complex hollow morphology, which difficultly deploys topology optimization structural techniques that use WAAM. In this paper, we develop a design strategy that unifies ground-structure optimization method with generative design that considers the features of hollow components, WAAM overhang angle limits and manufacturing thickness limits. The method is unique in that the user can interact with the design results, make changes to parameters, and alter the design based on the user's aesthetic or specific manufacturing setup needs. We deploy the method in the design and 3D printing of an optimized Electric Vehicle Chassis and successfully test in under different loading conditions.

Incremental Sheet Forming (ISF) is a flexible forming technology that can process parts without special mould, where-in an indenter moves over the surface of a sheet metal forming a 3D shell through localized deformation. Despite being fundamentally advantageous than stamping for low-volume production, there are many drawbacks to this technique, a major being the low geometrical accuracy of the achieved products, thereby limiting its widespread industrial application. In this paper, flexible support strategies and precise forming compensation have been considered as promising approaches in terms of improving the geometric accuracy in ISF. Four support strategies and a compensation forming method based on FEA and three-dimensional scanning are discussed in detail. Finally, we deploy the technique for the manufacturing of automotive products. The technique is applied to several automotive products of varying topologies and thus form the basis for successful verification of our technique.