Material issues in additive manufacturing: A review

Propulsion system development requires new, more affordable manufacturing techniques and technologies in a constrained budget environment, while future in-space applications will require in-space manufacturing and assembly of parts and systems. Marshall is advancing cuttingedge commercial capabilities in additive and digital manufacturing and applying them to aerospace challenges. The Center is developing the standards by which new manufacturing processes and parts will be tested and qualified. Rapidly evolving digital tools, such as additive manufacturing, are the leading edge of a revolution in the design and manufacture of space systems that enables rapid prototyping and reduces production times. Marshall has unique expertise in leveraging new digital tools, 3D printing, and other advanced manufacturing technologies and applying them to propulsion systems design and other aerospace materials to meet NASA mission and industry needs. Marshall is helping establish the standards and qualifications “from art to part” for the use of these advanced techniques and the parts produced using them in aerospace or elsewhere in the U.S. industrial base.

Additive manufacturing

Designing for Additive Manufacturing

Additive manufacturing processes, used for more than 25 years, are no longer confined to rapid prototyping applications. Mostly used nowadays in niche markets (medical applications, aerospace...) to manufacture metallic parts, they should provide improvements in terms of time-to-market, ecological impact and design compared to traditional industrial processes. Current metallic additive manufacturing studied in this paper are Selective Laser Sintering, Direct Metal Laser Sintering, Selective Laser Melting, Electron Beam Melting and Direct Metal Deposition. The performances of these processes are investigated through criteria derived from the time cost quality triangle and some prospects concerning these processes are given.

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Metallic additive manufacturing: state-of-the-art review and prospects

Smart manufacturing process and system automation – A critical review of the standards and envisioned scenarios

Substantial progress and development in additive manufacturing (AM) technologies have been realised during the last decade but have hardly been implemented on AM systems due to old numerical soluti...

STEP-NC digital thread for additive manufacturing: data model, implementation and validation

Additive Manufacturing (AM) is currently seen as an interesting process for the fabrication of complex and high value-added functional products. AM is being increasingly used in manufacturi...

Data model for additive manufacturing digital thread: state of the art and perspectives

Hierarchical object-oriented model (HOOM) for additive manufacturing digital thread

Additive manufacturing is, nowadays, a higher process than most traditional processes (machining, etc.). But there still remains a domain where this process is not very competitive: that being its digital chain. Indeed, it is too poor in information to allow for the development of advanced additive manufacturing operations and therefore to compete with the traditional processes. This paper proposes to use the STEP-NC concept, which contains high-level information, in order to integrate the additive manufacturing processes in a complete STEP-NC digital chain in accordance with the norm work group committee ISO TC 184/SC 1. This paper proposes to develop this digital chain with a classical CNC controller, which is also present in machining equipment, and to hence benefit from their development possibilities.

A new digital chain for additive manufacturing processes

Additive manufacturing (AM) technologies allow the manufacturing of parts directly from 3D models. These technologies, initially focused on rapid prototyping applications, have been increasingly considered for the production of final functional parts with high value added. The strengths and advantages of current AM processes include support for improved geometry for complex parts, reduction in tooling costs, material savings, and reduction in design to manufacturing lead-times. Along with those benefits, there are still production quality and performance factors, such as dimensional accuracy, strength of parts, and surface roughness, which may need to be improved depending on the product requirements. Therefore, there is a demand to increase the understanding of how AM production factors influence the final part parameters. This paper focuses on the investigation and optimization of material consumption, manufacturing time and dimensional accuracy (including linear error and surface flatness), for fused deposition modeling (FDM) technology. A design of experiments (DOE) is planned, executed and analyzed. Results indicate that print speed and the number of contours are the most important factors for the quality of the final part of the FDM process studied. Further research may consider the same approach, and the factors presented could be extended for AM technologies.

Renan Bonnard

Papers

STEP-NC digital thread for additive manufacturing: data model, implementation and validation

Data model for additive manufacturing digital thread: state of the art and perspectives

Hierarchical object-oriented model (HOOM) for additive manufacturing digital thread

A new digital chain for additive manufacturing processes

Optimizing additive manufacturing parameters for the fused deposition modeling technology using a design of experiments