I. the origin of species by means of natural selection

The past few decades have seen substantial growth in Additive Manufacturing (AM) technologies. However, this growth has mainly been process-driven. The evolution of engineering design to take advantage of the possibilities afforded by AM and to manage the constraints associated with the technology has lagged behind. This paper presents the major opportunities, constraints, and economic considerations for Design for Additive Manufacturing. It explores issues related to design and redesign for direct and indirect AM production. It also highlights key industrial applications, outlines future challenges, and identifies promising directions for research and the exploitation of AM's full potential in industry.

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Design for additive manufacturing: trends, opportunities, considerations, and constraints

3D printing with polymers: Challenges among expanding options and opportunities.

3D printing of Aluminium alloys: Additive Manufacturing of Aluminium alloys using selective laser melting

Design for manufacture and assembly (DFM) has typically meant that designers should tailor their designs to eliminate manufacturing difficulties and minimize manufacturing, assembly, and logistics costs. However, the capabilities of additive manufacturing technologies provide an opportunity to rethink DFM to take advantage of the unique capabilities of these technologies. As mentioned in Chap. 16, several companies are now using AM technologies for production manufacturing. For example, Siemens, Phonak, Widex, and the other hearing aid manufacturers use selective laser sintering and stereolithography machines to produce hearing aid shells; Align Technology uses stereolithography to fabricate molds for producing clear dental braces (“aligners”); and Boeing and its suppliers use polymer powder bed fusion (PBF) to produce ducts and similar parts for F-17 fighter jets. For hearing aids and dental aligners, AM machines enable manufacturing of tens to hundreds of thousands of parts, where each part is uniquely customized based upon person-specific geometric data. In the case of aircraft components, AM technology enables low-volume manufacturing, easy integration of design changes and, at least as importantly, piece part reductions to greatly simplify product assembly.

Design for Additive Manufacturing

Thermal issues in machine tools

Additive manufacturing technologies are increasingly used in the development of new products. However, variations in part quality in terms of material properties, dimensional tolerances, surface roughness and defects limit its broader acceptance. Process control today based on heuristics and experimental data yields limited improvement in part quality. In an effort to identify the needed measurement science for real-time closed-loop control of additive manufacturing (AM) processes, this paper presents a literature review on the current AM control schemes, process measurements and modelling and simulation methods as it applies to the powder bed fusion process, though results from other processes are reviewed where applicable. We present our research findings to identify the correlations between process parameters, process signatures and product quality. We also present research recommendations on the key control issues to serve as a technical basis for standards development in this area. Complimentary deta...

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A review on measurement science needs for real-time control of additive manufacturing metal powder bed fusion processes

Historically, standardized test parts are used to quantitatively evaluate the performance of a machine or process While several different additive manufacturing (AM) test parts have been developed in the past, there are no current standard test parts This paper reviews existing AM test parts, discusses the purposes of the studies, and describes important features and characteristics found in these test parts A new test part intended for standardization is proposed This part incorporates the most useful features seen in previous test parts These features are designed to highlight process capabilities and test machine accuracy The design has been validated through builds by several AM processes

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Proposal for a Standardized Test Artifact for Additive Manufacturing Machines and Processes

A test artifact, intended for standardization, is proposed for the purpose of evaluating the performance of additive manufacturing (AM) systems. A thorough analysis of previously proposed AM test artifacts as well as experience with machining test artifacts have inspired the design of the proposed test artifact. This new artifact is designed to provide a characterization of the capabilities and limitations of an AM system, as well as to allow system improvement by linking specific errors measured in the test artifact to specific sources in the AM system. The proposed test artifact has been built in multiple materials using multiple AM technologies. The results of several of the builds are discussed, demonstrating how the measurement results can be used to characterize and improve a specific AM system.

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An Additive Manufacturing Test Artifact.

/pdf/effects-of-powder-recycling-on-stainless-steel-powder-and-50gzwoi2h0.pdf

M. Alkan Donmez

Papers

Thermal issues in machine tools

A review on measurement science needs for real-time control of additive manufacturing metal powder bed fusion processes

Proposal for a Standardized Test Artifact for Additive Manufacturing Machines and Processes

An Additive Manufacturing Test Artifact.

Effects of powder recycling on stainless steel powder and built material properties in metal powder bed fusion processes