The role of Technical Functional Analysis in innovative design of bespoke Rapid Manufactured parts: medical industry applications LUPEANU M.E.*, ROŞU M.M.*, RENNIE A.E.W.**, NEAGU C.*, BROOKS H.L*** *Manufacturing Department, Politehnica University of Bucharest, Splaiul Independenţei No. 313, Romania ** Engineering Department Lancaster University Lancaster LA1 4YR, United Kingdom ***University of Central Lancashire, Preston PR1 2HE, United Kingdom mihaela.lupeanu@yahoo.com, magdalenarosu@yahoo.com, a.rennie@lancaster.ac.uk, necor_upb@yahoo.com, HLBrooks@uclan.ac.uk Abstract: A variety of methods and tools for product design have been developed and introduced in recent years within high-tech enterprises to improve their competitiveness. The positive consequences of their use are indisputable: without them, it would not be possible to shorten development cycles, reduce costs and improve product quality and reliability. Deploying Technical Functional Analysis (TFA) techniques in the field of additive manufacturing (AM) brings the following significant benefits: lower costs; reduction in material consumption; reduction in manufacturing time; shorter time-to-market; improving the accuracy of certain operations; improving the efficiency of studied processes and procedures. The design of a product determines: functions; choice of materials; dimensions; design; performance; assembly conditions; tolerances etc. Consequently, quality and cost (future costs) are attributable to 70-75% following the end of the design phase. The application of TFA, along with methods that involve a better understanding of the design process, favours taking the best decisions in the early stages, thus reducing the final costs. This paper shows that using TFA in the development process for AM-enabled bespoke products, ensures that the best decisions on product and process concepts have been made from these early stages. Key-Words: bespoke design, life-cycle analysis, technical functional analysis, innovative design, additive manufacturing, function definition 1 Introduction In the medical field, additive manufacturing (AM) is used in applications such as hearing instruments, dental restorations, surgical drill guides, anatomical models, orthopaedic implants and the latest innovative application of bio-manufacturing and tissue engineering [1]. More cost effective technologies, such as 3D Printing and Selective Laser Melting (SLM) have recently come to the scene and definitely require a fresh re-consideration for medical applications [2, 3]. Targeted FA allows optimisation of products according to the costumers needs, taking into consideration all aspects of life of the product. The novelty of this paper is introducing technical FA as a tool for optimising bespoke products used in the medical industry. The analysis has been targeted on custom-fitted surgical products in order to improve functional, design, and usage characteristics [4]. TFA is a method that can be applied in any lifecycle stage of a product, but it is mainly used in the primary stages: pre-conception; conception; and first part of product development. It can be used either for redesigning existing products, or for designing innovative products starting with the need. The approach proposed by the authors is different due to the specificity of the medical field and the end use of the products that are being designed. Advances in Production, Automation and Transportation Systems ISBN: 978-1-61804-193-7 227