Journal ArticleDOI
Economics of additive manufacturing for end-usable metal parts
Eleonora Atzeni,Alessandro Salmi +1 more
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In this paper, a comparison between two different technologies for metal part fabrication, the traditional high-pressure die-casting and the direct metal laser sintering additive technique, is done with consideration of both the geometric possibilities of AM and the economic point of view.Abstract:
Additive manufacturing (AM) of metal parts combined with part redesign has a positive repercussion on cost saving. In fact, a remarkable cost reduction can be obtained if the component shape is modified to exploit AM potentialities. This paper deals with the evaluation of the production volume for which AM techniques result competitive with respect to conventional processes for the production of end-usable metal parts. For this purpose, a comparison between two different technologies for metal part fabrication, the traditional high-pressure die-casting and the direct metal laser sintering additive technique, is done with consideration of both the geometric possibilities of AM and the economic point of view. A design for additive manufacturing approach is adopted. Costs models of both processes are identified and then applied to an aeronautical component selected as case study. This research evidences that currently additive techniques can be economically convenient and competitive to traditional processes for small to medium batch production of metal parts.read more
Citations
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Dissertation
Reverse engineering of obsolete components for realisation using additive manufacturing
TL;DR: In this paper, the authors investigated the possibilities that AM presents for realising the manufacture of obsolete parts from older systems and investigated the benefits and drawbacks of using AM for reverse engineering.
Journal ArticleDOI
A large format DMLM system using a continuously rotating powder bed
William Thomas Carter,Michael Evans Graham,Christopher James Hayden,Younkoo Jeong,Justin Mamrak,Brian Mccarthy,William Francis Monaghan,Edward James Nieters,Victor Petrovich Ostroverkhov,Subhrajit Roychowdhury,Andrea Schmitz,Mohammed Nader Shalaby,Michael R. Tucker +12 more
TL;DR: In this article, a Direct Metal Laser Melting (DMLM) architecture is proposed for aircraft engine combustor linings, which incorporates a rotating powder bed with an ascending laser scanner and recoater to build parts in a helical fashion.
Journal ArticleDOI
Design for Additive Manufacturing and for Machining in the Automotive Field
TL;DR: In this article, an aluminum component for automotive application was redesigned through topology optimization and Design for Additive Manufacturing (DFM) in order to facilitate the machining operations after additive construction, and the optical dimensional check proved a good correspondence with the tolerances predicted by process simulation and confirmed part acceptability.
References
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Book
Additive Manufacturing Technologies: Rapid Prototyping to Direct Digital Manufacturing
TL;DR: Gibson et al. as discussed by the authors presented a comprehensive overview of additive manufacturing technologies plus descriptions of support technologies like software systems and post-processing approaches, and provided systematic solutions for process selection and design for AM Additive Manufacturing Technologies: Rapid Prototyping to Direct Digital Manufacturing.
BookDOI
Rapid manufacturing : an industrial revolution for the digital age
TL;DR: In this paper, the authors present a discussion of the potential of rapid manufacturing in the automotive industry and present a case study of how to modify a garden fork handle in order to make it more efficient.
Journal ArticleDOI
Rapid Manufacturing of Metal Components by Laser Forming
TL;DR: In this article, the main driving force of rapid prototyping or layer manufacturing techniques changed from fabrication of prototypes to rapid tooling (RT) and rapid manufacturing (RM), and nowadays, the direct fabrication of functional or structural end-use products made by layer manufacturing methods, i.e. RM, is the main trend.
Book ChapterDOI
Design for Additive Manufacturing
TL;DR: In this article, the capabilities of additive manufacturing technologies provide an opportunity to rethink DFM to take advantage of the unique capabilities of these technologies, and several companies are now using AM technologies for production manufacturing.
Journal ArticleDOI
Cost estimation for rapid manufacturing - laser sintering production for low to medium volumes:
TL;DR: In this article, a cost model for laser sintering is proposed, which leads to graph profiles that are typical for layer-by-layer manufacturing processes, and the evolution of cost models and the indirect cost significance in modern costing representation is shown.