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Additive manufacturing (AM) of metallic parts provides engineers with unprecedented design freedom. This enables designers to consolidate assemblies, lightweight designs, create intricate internal geometries for enhanced fluid flow or heat transfer performance, and fabricate complex components that previously could not be manufactured. While these design benefits may come “free” in many cases, it necessitates an understanding of the limitations and capabilities of the specific AM process used for production, the system-level design intent, and the postprocessing and inspection/qualification implications. Unfortunately, design for additive manufacturing (DfAM) guidelines for metal AM processes are nascent given the rapid advancements in metal AM technology recently. In this paper, we present a case study to provide insight into the challenges that engineers face when redesigning a multicomponent assembly …