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In the development of innovative and high-performance products, design expertise is a critical factor. Nevertheless, novel manufacturing processes often frequently lack an accessible comprehensive knowledge base for product developers. To tackle this deficiency in the context of emerging additive manufacturing processes, substantial design knowledge has already been established. However, novel additive manufacturing processes like continuous fiber-reinforced material extrusion have often been disregarded, complicating the process's wider dissemination. The importance of design knowledge availability is paramount, as well as the need for user-friendly design knowledge preparation, standardized structure, and methodological support for accessing the accumulated knowledge with precision. In this paper, we present an approach that provides formalized opportunistic and restrictive design knowledge, ensuring both the comprehensive exploitation of process-specific potentials and the consideration of restrictive limitations in the construction of components. Opportunistic knowledge, presented as principle cards, is systematically derived, prepared, and made accessible. Moreover, an access system is developed to ensure the comprehensive utilization of process-specific potentials throughout the development process. Furthermore, we propose linking these principles through a synergy and conflict matrix, aiming to consider synergistic principles and identify potential conflicts at an early stage. Additionally, an approach to provide restrictive design knowledge in the form of a design rule catalog is proposed. The application of the knowledge system is demonstrated exemplarily using a weight-optimized component. [ABSTRACT FROM AUTHOR]

Continuous fiber-reinforced material extrusion is an emerging additive manufacturing process that builds components layer by layer by extruding a continuous fiber-reinforced thermoplastic strand. This novel manufacturing process combines the benefits of additive manufacturing with the mechanical properties and lightweight potential of composite materials, making it a promising approach for creating high-strength end products. The field of design for additive manufacturing has developed to provide suitable methods and tools for such emerging processes. However, continuous fiber-reinforced material extrusion, as a relatively new technology, has not been extensively explored in this context. Designing components for this process requires considering both restrictive and opportunistic aspects, such as extreme anisotropy and opportunities for functional integration. Existing process models and methods do not adequately address these specific needs. To bridge this gap, a tailored methodology for designing continuous fiber-reinforced material extrusion is proposed, building on established process models. This includes developing process-specific methods and integrating them into the process model, such as a process selection analysis to assess the suitability of the method and a decision model for selecting the process for highly stressed components. Additionally, a detailed design process tailored to continuous fiber-reinforced material extrusion is presented. The application of the developed process model is demonstrated through a case study.