Additive Manufacturing (AM) has a profound impact on mass customization of products. To satisfy the product requirements while keep profitability and sustainability, reducing the energy and resource consumption is one of key solutions. This research presents a product family design process driven by consideration of resource consumption. A family of light-weight structures was designed by applying topology optimization algorithm to achieve required performance and weight. Finite Element Analysis (FEA) tools were used to simulate the mechanical behavior of the products. To demonstrate the applicability of the proposed method, nine samples within the designed product family were fabricated by additive manufacturing. Resource consumption measured by manufacturing cost and build time was analyzed for each sample. The result shows feasibility of designing a product family using resource consideration as a guideline.