Article: Feasibility of additive manufacturing for personalised lighting design: a multi-criteria assessment of process capability, optical performance and techno-economic viability Journal: International Journal of Reasoning-based Intelligent Systems (IJRIS) 2026 Vol.18 No.19 pp.63 - 75 Abstract: Personalised luminaires are increasingly demanded in architectural and consumer lighting, but conventional tooling-based manufacturing is poorly suited to low-volume customised production. This paper presents the integrated luminaire additive feasibility framework, a ten-stage analytical method for assessing additive manufacturing feasibility across process capability, optical performance, thermal management, techno-economic viability and regulatory readiness. Four platforms - stereolithography, digital light processing, fused filament fabrication and material jetting - are compared for optical, structural and thermal luminaire subsystems. Using literature-derived data and scenario modelling, the study shows that post-processed transparent resins can achieve 88%-92% luminous transmittance, while PLA diffusers provide tuneable 20%-65% transmittance. Break-even analysis indicates additive manufacturing is viable below approximately 800-3,000 units for optics and 5,000-10,000 units for housings. Digital light processing achieves the highest weighted feasibility score. Results provide a screening-level decision framework rather than experimental validation. Inderscience Publishers - linking academia, business and industry through research

Title: Feasibility of additive manufacturing for personalised lighting design: a multi-criteria assessment of process capability, optical performance and techno-economic viability

Authors: Xin Yang

Addresses: College of Art and Design, Huainan Normal University, Huainan, Anhui, 232038, China

Abstract: Personalised luminaires are increasingly demanded in architectural and consumer lighting, but conventional tooling-based manufacturing is poorly suited to low-volume customised production. This paper presents the integrated luminaire additive feasibility framework, a ten-stage analytical method for assessing additive manufacturing feasibility across process capability, optical performance, thermal management, techno-economic viability and regulatory readiness. Four platforms - stereolithography, digital light processing, fused filament fabrication and material jetting - are compared for optical, structural and thermal luminaire subsystems. Using literature-derived data and scenario modelling, the study shows that post-processed transparent resins can achieve 88%-92% luminous transmittance, while PLA diffusers provide tuneable 20%-65% transmittance. Break-even analysis indicates additive manufacturing is viable below approximately 800-3,000 units for optics and 5,000-10,000 units for housings. Digital light processing achieves the highest weighted feasibility score. Results provide a screening-level decision framework rather than experimental validation.

Keywords: additive manufacturing; personalised lighting design; luminaire feasibility; freeform optics; digital light processing; DLP; techno-economic analysis; mass customisation; optical transmittance.

DOI: 10.1504/IJRIS.2026.155634

International Journal of Reasoning-based Intelligent Systems, 2026 Vol.18 No.19, pp.63 - 75

Received: 22 Apr 2026
Accepted: 03 Jun 2026
Published online: 07 Aug 2026 *

Title: Feasibility of additive manufacturing for personalised lighting design: a multi-criteria assessment of process capability, optical performance and techno-economic viability

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