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Additive manufacturing is considered a key technology for digital production. However, several barriers towards the broad industrial application exist, e.g. the associated cost and the required experience regarding the manufacturing process. To eradicate these barriers, the complete digitalization of the value creation process is needed. In this thesis, a digital, automated support structure design procedure is developed. Topology optimization is used for design rule determination, and the space colonization algorithm is adapted for the automated design. The validity of the procedure is proven experimentally, revealing sufficient mechanical performance alongside cost reduction at medium to large production scales. The content Provides a concise review of support structure optimization in laser powder bed fusion Includes thermo-mechanical material model of Ti-6Al-4V alloy Contains cost model for calculation of support-induced costs The author Katharina Bartsch studied mechanical engineering with a focus on product development, materials and production at the Technical University of Hamburg. Here, she received her doctorate in 2022 under Prof. Dr.-Ing. Claus Emmelmann (Institute for Laser and System Technologies - iLAS). During her time as a doctoral candidate, she worked as a research associate as well as chief engineer (since 2020) at the iLAS and as a team leader and research associate (since 2019) at the LZN Laser Zentrum Nord GmbH, later Fraunhofer Research Institution for Additive Production Technologies IAPT.
Additive manufacturing is considered a key technology for digital production. However, several barriers towards the broad industrial application exist, e.g. the associated cost and the required experience regarding the manufacturing process. To eradicate these barriers, the complete digitalization of the value creation process is needed. In this thesis, a digital, automated support structuredesign procedure is developed. Topology optimization is used for design rule determination, and the space colonization algorithm is adapted for the automated design. The validity of the procedure is proven experimentally, revealing sufficient mechanical performance alongside cost reduction at medium to large production scales.
Laser powder bed fusion of metals is a technology that makes use of a laser beam to selectively melt metal powder layer-by-layer in order to fabricate complex geometries in high performance materials. The technology is currently transforming aerospace and biomedical manufacturing and its adoption is widening into other industries as well, including automotive, energy, and traditional manufacturing. With an increase in design freedom brought to bear by additive manufacturing, new opportunities are emerging for designs not possible previously and in material systems that now provide sufficient performance to be qualified in end-use mission-critical applications. After decades of research and development, laser powder bed fusion is now enabling a new era of digitally driven manufacturing. Fundamentals of Laser Powder Bed Fusion of Metals will provide the fundamental principles in a broad range of topics relating to metal laser powder bed fusion. The target audience includes new users, focusing on graduate and undergraduate students; however, this book can also serve as a reference for experienced users as well, including senior researchers and engineers in industry. The current best practices are discussed in detail, as well as the limitations, challenges, and potential research and commercial opportunities moving forward. Presents laser powder bed fusion fundamentals, as well as their inherent challenges Provides an up-to-date summary of this advancing technology and its potential Provides a comprehensive textbook for universities, as well as a reference for industry Acts as quick-reference guide
This textbook and reference provides a comprehensive treatment of additive manufacturing (AM) for metals, including design and digital work flows, process science and reliability, metallic systems, quality assurance, and applications. The book is rooted in the fundamental science necessary to develop and understand AM technologies, as well as the application of engineering principles covering several disciplines to successfully exploit this important technology. As additive manufacturing of metals is the fastest growing subset of this transformative technology, with the potential to make the widest impact to industrial production, Metals Additive Manufacturing: Design, Processes, Materials, Quality Assurance, and Applications is ideal for students in a range of engineering disciplines and practitioners working in aerospace, automotive, medical device manufacturing industries.
This book presents the Proceedings of the 3rd conference on Additive Manufacturing in Products and Applications AMPA2023, a conference that brought together engineers, designers, and managers to exchange ideas and knowledge on how to support real-world value chains by developing additive manufactured serial products. It covers a range of topics related to additive manufacturing (AM), including design for AM, physical and digital process chains, as well as for technology transfer into companies and applications. The book is divided in Sections such as Design for AM, Digital Process Chains, Emerging AM Technologies and Teaching & Training. In addition to these technical topics, the book also covers broader issues related to additive manufacturing, such as Manufacturing Readiness Levels, implementing AM machines into the existing production chain, and quality assurance and control mechanisms.
This book offers a unique guide to the three-dimensional (3D) printing of metals. It covers various aspects of additive, subtractive, and joining processes used to form three-dimensional parts with applications ranging from prototyping to production. Examining a variety of manufacturing technologies and their ability to produce both prototypes and functional production-quality parts, the individual chapters address metal components and discuss some of the important research challenges associated with the use of these technologies. As well as exploring the latest technologies currently under development, the book features unique sections on electron beam melting technology, material lifting, and the importance this science has in the engineering context. Presenting unique real-life case studies from industry, this book is also the first to offer the perspective of engineers who work in the field of aerospace and transportation systems, and who design components and manufacturing networks. Written by the leading experts in this field at universities and in industry, it provides a comprehensive textbook for students and an invaluable guide for practitioners
This engaging volume presents the exciting new technology of additive manufacturing (AM) of metal objects for a broad audience of academic and industry researchers, manufacturing professionals, undergraduate and graduate students, hobbyists, and artists. Innovative applications ranging from rocket nozzles to custom jewelry to medical implants illustrate a new world of freedom in design and fabrication, creating objects otherwise not possible by conventional means. The author describes the various methods and advanced metals used to create high value components, enabling readers to choose which process is best for them. Of particular interest is how harnessing the power of lasers, electron beams, and electric arcs, as directed by advanced computer models, robots, and 3D printing systems, can create otherwise unattainable objects. A timeline depicting the evolution of metalworking, accelerated by the computer and information age, ties AM metal technology to the rapid evolution of global technology trends. Charts, diagrams, and illustrations complement the text to describe the diverse set of technologies brought together in the AM processing of metal. Extensive listing of terms, definitions, and acronyms provides the reader with a quick reference guide to the language of AM metal processing. The book directs the reader to a wealth of internet sites providing further reading and resources, such as vendors and service providers, to jump start those interested in taking the first steps to establishing AM metal capability on whatever scale. The appendix provides hands-on example exercises for those ready to engage in experiential self-directed learning.
Clinical Applications of Digital Dental Technology Comprehensive overview of digital dentistry describing available technologies and when/how to use digital dentistry in practice Clinical Applications of Digital Dental Technology provides comprehensive yet practical references to a wide range of potential uses for digital technology in dental practice, discussing a wide range of digital technologies including their indications, contraindications, advantages, disadvantages, limitations, and applications. Overall, the book emphasizes how to use digital dentistry in daily practice across all specialties. With broad coverage of the subject, Clinical Applications of Digital Dental Technology discusses digital imaging, digital impressions, digital prosthodontics, digital implant planning and placement, and digital applications in endodontics, orthodontics, and oral surgery. Each chapter is written by experts in each topic and covers applications for prosthodontics, implant dentistry, oral surgery, endodontics, orthodontics, and other specialty areas. Clinical Applications of Digital Dental Technology also includes information on: Software, scanning, and manufacturing capabilities which have led to an unparalleled revolution leading to a major paradigm shift in all aspects of dentistry Digital radiography, virtual planning, computer-aided design and manufacturing, digital impressions, digitally fabricated dentures, and the “virtual patient” Available technologies, plus a critical evaluation of each one to detail how they are incorporated in daily practice across all specialties Developing technologies in the field with special attention paid to those expected to be on the market sometime in the near future Clinical Applications of Digital Dental Technology is an essential resource for general dentists, specialists, and students who wish to understand digital dentistry and efficiently and intelligently incorporate it into their practices. The text is also useful for laboratory technicians interested in recent digital advances in the dental field.
Additive manufacturing (AM) is a fast-growing sector with the ability to evoke a revolution in manufacturing due to its almost unlimited design freedom and its capability to produce personalised parts locally and with efficient material use. AM companies, however, still face technological challenges such as limited precision due to shrinkage, built-in stresses and limited process stability and robustness. Moreover, often post-processing is needed due to high roughness and remaining porosity. Qualified, trained personnel are also in short supply. In recent years, there have been dramatic improvements in AM design methods, process control, post-processing, material properties and material range. However, if AM is going to gain a significant market share, it must be developed into a true precision manufacturing method. The production of precision parts relies on three principles: Production is robust (i.e. all sensitive parameters can be controlled). Production is predictable (for example, the shrinkage that occurs is acceptable because it can be predicted and compensated in the design). Parts are measurable (as without metrology, accuracy, repeatability and quality assurance cannot be known). AM of metals is inherently a high-energy process with many sensitive and inter-related process parameters, making it susceptible to thermal distortions, defects and process drift. The complete modelling of these processes is beyond current computational power, and novel methods are needed to practicably predict performance and inform design. In addition, metal AM produces highly textured surfaces and complex surface features that stretch the limits of contemporary metrology. With so many factors to consider, there is a significant shortage of background material on how to inject precision into AM processes. Shortage in such material is an important barrier for a wider uptake of advanced manufacturing technologies, and a comprehensive book is thus needed. This book aims to inform the reader how to improve the precision of metal AM processes by tackling the three principles of robustness, predictability and metrology, and by developing computer-aided engineering methods that empower rather than limit AM design. Richard Leach is a professor in metrology at the University of Nottingham and heads up the Manufacturing Metrology Team. Prior to this position, he was at the National Physical Laboratory from 1990 to 2014. His primary love is instrument building, from concept to final installation, and his current interests are the dimensional measurement of precision and additive manufactured structures. His research themes include the measurement of surface topography, the development of methods for measuring 3D structures, the development of methods for controlling large surfaces to high resolution in industrial applications and the traceability of X-ray computed tomography. He is a leader of several professional societies and a visiting professor at Loughborough University and the Harbin Institute of Technology. Simone Carmignato is a professor in manufacturing engineering at the University of Padua. His main research activities are in the areas of precision manufacturing, dimensional metrology and industrial computed tomography. He is the author of books and hundreds of scientific papers, and he is an active member of leading technical and scientific societies. He has been chairman, organiser and keynote speaker for several international conferences, and received national and international awards, including the Taylor Medal from CIRP, the International Academy for Production Engineering.