This study highlights a data-driven optimization project in additive manufacturing that delivered major performance and supply chain improvements for a military vehicle door hinge. Using data, AI, and the Citrine Platform, ADAPT and its partners optimized build parameters faster than traditional methods, resulting in a hinge that is 38% lighter, 50% stronger, and 84% less complex by reducing the design from six parts to one. Inventory needs were eliminated through 100% on-demand production, improving readiness in case of failure. The use of high-performance materials and geometric optimization led to stronger, more reliable hinges with fewer failures, demonstrating how advanced data-driven approaches can accelerate development, enhance durability, and modernize manufacturing for defense ap

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