Reducing return rates and improving product fit through additive manufacturing

Abstract

Published in SOAR: Shocker Open Access Repository by Wichita State University Libraries Technical Services, November 2025. 2025 IEMS Officers: Gamal Weheba (Conference Chair); Hesham Mahgoub (Program Chair); Dalia Mahgoub (Technical Director); Ed Sawan (Publications Editor); Wilfredo Moscoso (Proceedings Editor); Abdulaziz G. Abdulaziz (Associate Editor)High product return rates create major financial, environmental, and reputational challenges for industries such as fashion, footwear, and medical devices. Many of these returns stem from poor product fit, design flaws, and unmet customer expectations. Additive Manufacturing (AM), or 3D printing, offers solutions through customization, prototyping, and reduced material waste. This paper explores how AM improves product quality and customer satisfaction, leading to lower return rates across multiple sectors. Challenges such as material limits, data accuracy, and lack of standardization are also discussed. Overall, AM shows strong potential to support sustainable manufacturing while reducing costs and building consumer trust