This work proposes a comprehensive exploration into the optimization of morphing wing trailing edges, emphasizing the integration of additive manufacturing constraints into XFEM levelset approaches. The methodology incorporates specific considerations to address the complexities inherent in additive manufacturing processes, offering a robust solution for enhanced wing design. Additive manufacturing presents unique challenges, notably the mitigation of overhangs, which significantly impact print quality and structural integrity. Our approach integrates strategies to minimize overhangs, ensuring smoother manufacturing processes and reducing the need for support structures, thereby enhancing the manufacturability of the optimized wing design. The XFEM levelset method provides precise stress estimations via explicit interfaces, unlike density-based methods (especially for gray-scale phase). Our unique integration of XFEM with density-based approaches enables hole creation during optimization, refining the process for structural strength and morphing abilities. This approach is included in Morfeo, our standalone in-house software, [1]. By addressing overhang challenges and leveraging XFEM's explicit interface representation, this study aims to improve wing design optimization. The incorporation of these elements into the topology optimization process not only enhances the manufacturability of the design but also ensures a high degree of structural reliability and performance, marking a significant advancement in morphing wing technology.