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Additive Manufacturing (AM) brought new design freedom and possibilities that enable design and manufacturing of products with new forms and functionalities. To utilise these possibilities a new design approach emerged, Design for Additive Manufacturing (DfAM), that contains methods and tools for supporting AM oriented design process. Designers working with AM are aware of the need to apply DfAM and AM possibilities in conceptual design phase where they have the most significant influence on product architecture and form but are facing a lack of suitable DfAM approaches for early design phases. Therefore, the presented research is investigating possibilities of storing and representing AM knowledge in the form of design principles to be used in the conceptual design phase. The paper proposes conceiving of Design Principles for Additive Manufacturing repository where formalised AM knowledge is stored in the form of design principles and structured based on function criteria. In the paper, various elements of design principle representation are discussed, as well as their role in the conceptual design process.

Use of virtual reality (VR) is considered beneficial for reviewing 3D models throughout product design. However, research on its usability in the design field is still explorative, and previous studies are often contradictory regarding the usability of VR for 3D model review. This paper argues that the usability of VR should be assessed by analysing human factors such as spatial perception and taking into consideration the complexity of the reviewed product. Hence, a comparative evaluation study has been conducted to assess spatial perception in desktop interface-based and VR-based review of 3D models of products with different levels of complexity. The results show that participants in VR more could perceive the fit of user interface elements, and estimation of the model dimensions had a lower relative error than in desktop interface. It has been found that various sensory cues are used to perceive the model size and that the employed sensory cues depend on the level of complexity. Finally, it is proposed that differences between a desktop interface and VR for reviewing models are more evident when reviewing models of higher complexity levels.

Sketching-related activities are considered as an essential form of communication in the early phases of a design process. In the presented study, it is argued that both the sketching and the sketch-related verbalisations are reflected in the level of elaboration of the sketching outputs. Hence, a protocol study was conducted to analyse the frequencies of different sketching-related activities during team conceptual design sessions and the associated levels of elaboration for each of the sketching outputs in the form of concept drawings. The results show that although teams generate sketches of various number, complexity and clarity, there exist commonalities across the studied experiment sessions. For example, teams share a pattern of developing solutions without transformations or using lateral transformations within the first part of the sessions and using vertical transformations to produce final concepts towards the end of the sessions. Moreover, teams used associated sketch elements to start drawing new sketches and then alternated to other activities, most of all verbal explanation, for the sake of elaboration and better understanding.

Studies of design activity have been dominantly reporting on different aspects of the design process, rather than the content of designing. The aim of the presented research has been the development and application of an approach for a fine-grain analysis of the design content communicated between designers during the team conceptual design activities. The proposed approach builds on an engineering design ontology as a foundation for the content categorisation. Two teams have been studied using the protocol analysis method. The coded protocols offered fine-grain descriptions of the content communicated at different points in the design session and enabled comparison of teams’ approaches and deriving some generalisable findings. For example, it has been shown that both teams focused primarily on the use of the developed product and the operands within the technical process, in order to generate new technical solutions and initial component design. Moreover, teams exhibit progress from abstract to concrete solutions as the sessions proceeded and focused on the functional requirements towards the end of the sessions.