What are the key design considerations for metal additive manufacturing and how do they differ from traditional DFM?

Metal AM design considerations include: orientation planning for support minimization and surface quality, self-supporting angles (typically >45 degrees from horizontal), designing for powder removal from internal channels, adding machining allowances on critical surfaces, considering thermal distortion and residual stress, designing support structures for easy removal, implementing lattice structures for weight reduction while maintaining thermal paths. Unlike traditional DFM, AM enables complex internal channels, topology-optimized shapes, and consolidated assemblies. Post-processing requirements (heat treatment, HIP, machining) must be considered in design phase.