Additive manufacturing (AM) enables the production of innovative, lightweight component designs in the aerospace industry. However, AM processes introduce new production feasibility considerations that must be addressed during product development. Therefore, engineers require effective design support and a new design approach to fully exploit AM’s capabilities while balancing its constraints. Through an interview study involving 20 AM aerospace industry professionals from nine countries and 10 organisations, this research identifies AM design opportunities and challenges and explores the design supports used to achieve and overcome them. The findings indicate that Laser Powder Bed Fusion is a predominant AM process in aeronautical and space applications. Further, the study identifies practical and computational design supports, describes how AM design is approached during product development and provides a model outlining a general AM design approach. Key AM design challenges identified include insufficient knowledge of material properties, limited sharing of design knowledge and a lack of understanding of the relationship between AM design and post-processing requirements. Consequently, skills gaps and educational needs for Design for AM in aerospace engineering are highlighted. Additionally, the study suggests that further AM aerospace standards, enhanced computer-aided engineering software for AM and artificial intelligence integration could improve design support.