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Journal ArticleDOI

Laser based additive manufacturing in industry and academia

TL;DR: In this paper, an overview over laser-based additive manufacturing with comments on the main steps necessary to build parts to introduce the complexity of the whole process chain is presented. But despite good sales of AM machines, there are still several challenges hindering a broad economic use of AM.
About: This article is published in CIRP Annals.The article was published on 2017-01-01. It has received 415 citations till now. The article focuses on the topics: Advanced manufacturing.
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Journal ArticleDOI
06 Apr 2016
TL;DR: 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.
Abstract: 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.

481 citations

Journal ArticleDOI
28 May 2021-Science
TL;DR: In this article, a holistic concept of material-structure-performance integrated additive manufacturing (MSPI-AM) is proposed to cope with the extensive challenges of laser-based additive manufacturing.
Abstract: BACKGROUND Metallic components are the cornerstone of modern industries such as aviation, aerospace, automobile manufacturing, and energy production. The stringent requirements for high-performance metallic components impede the optimization of materials selection and manufacturing. Laser-based additive manufacturing (AM) is a key strategic technology for technological innovation and industrial sustainability. As the number of applications increases, so do the scientific and technological challenges. Because laser AM has domain-by-domain (e.g., point-by-point, line-by-line, and layer-by-layer) localized forming characteristics, the requisite for printing process and performance control encompasses more than six orders of magnitude, from the microstructure (nanometer- to micrometer-scale) to macroscale structure and performance of components (millimeter- to meter-scale). The traditional route of laser-metal AM follows a typical “series mode” from design to build, resulting in a cumbersome trial-and-error methodology that creates challenges for obtaining high-performance goals. ADVANCES We propose a holistic concept of material-structure-performance integrated additive manufacturing (MSPI-AM) to cope with the extensive challenges of AM. We define MSPI-AM as a one-step AM production of an integral metallic component by integrating multimaterial layout and innovative structures, with an aim to proactively achieve the designed high performance and multifunctionality. Driven by the performance or function to be realized, the MSPI-AM methodology enables the design of multiple materials, new structures, and corresponding printing processes in parallel and emphasizes their mutual compatibility, providing a systematic solution to the existing challenges for laser-metal AM. MSPI-AM is defined by two methodological ideas: “the right materials printed in the right positions” and “unique structures printed for unique functions.” The increasingly creative methods for engineering both micro- and macrostructures within single printed components have led to the use of AM to produce more complicated structures with multimaterials. It is now feasible to design and print multimaterial components with spatially varying microstructures and properties (e.g., nanocomposites, in situ composites, and gradient materials), further enabling the integration of functional structures with electronics within the volume of a laser-printed monolithic part. These complicated structures (e.g., integral topology optimization structures, biomimetic structures learned from nature, and multiscale hierarchical lattice or cellular structures) have led to breakthroughs in both mechanical performance and physical/chemical functionality. Proactive realization of high performance and multifunctionality requires cross-scale coordination mechanisms (i.e., from the nano/microscale to the macroscale). OUTLOOK Our MSPI-AM continues to develop into a practical methodology that contributes to the high performance and multifunctionality goals of AM. Many opportunities exist to enhance MSPI-AM. MSPI-AM relies on a more digitized material and structure development and printing, which could be accomplished by considering different paradigms for AM materials discovery with the Materials Genome Initiative, standardization of formats for digitizing materials and structures to accelerate data aggregation, and a systematic printability database to enhance autonomous decision-making of printers. MSPI-oriented AM becomes more intelligent in processes and production, with the integration of intelligent detection, sensing and monitoring, big-data statistics and analytics, machine learning, and digital twins. MSPI-AM further calls for more hybrid approaches to yield the final high-performance/multifunctional achievements, with more versatile materials selection and more comprehensive integration of virtual manufacturing and real production to navigate more complex printing. We hope that MSPI-AM can become a key strategy for the sustainable development of AM technologies. Download high-res image Open in new tab Download Powerpoint Material-structure-performance integrated additive manufacturing (MSPI-AM). Versatile designed materials and innovative structures are simultaneously printed within an integral metallic component to yield high performance and multifunctionality, integrating in parallel the core elements of material, structure, process, and performance and a large number of related coupling elements and future potential elements to enhance the multifunctionality of printed components and the maturity and sustainability of laser AM technologies.

386 citations

Journal ArticleDOI
TL;DR: An innovative framework both highlighting the links between I4.0 and CE and unveiling future research fields has been developed, and results show as it is possible to enhance a set of different relations.
Abstract: Industry 4.0 (I4.0) and Circular Economy (CE) are undoubtedly two of the most debated topics of the last decades. Progressively, they gained the interest of policymakers, practitioners and scholars...

322 citations


Cites background from "Laser based additive manufacturing ..."

  • ...2018; Sauerwein, Bakker, and Balkenende 2017) processes (Schmidt et al. 2017; Syed-Khaja, Perez, and Franke 2016)....

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  • ..., and Bugtai 2017) x (Rødseth, Schjølberg, and Marhaug 2017) x (Sauerwein, Bakker, and Balkenende 2017) x (Schmidt et al. 2017) x (Schroeder et al....

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  • ...2018) x (Sauerwein, Bakker, and Balkenende 2017) x (Sauerwein and Doubrovski 2018) x (Schmidt et al. 2017) x (Sheng Yang et al....

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  • ...…2017; Sheng Yang et al. 2017), (ii) improve the impacts and energy consumption (Ma et al. 2018; Minetola and Eyers 2018), or (iii) improve product development and design (Müller et al. 2018; Sauerwein, Bakker, and Balkenende 2017) processes (Schmidt et al. 2017; Syed-Khaja, Perez, and Franke 2016)....

    [...]

01 Aug 2010
TL;DR: Stereolithography is a solid freeform technique (SFF) that was introduced in the late 1980s as discussed by the authors, which has the highest fabrication accuracy and an increasing number of materials that can be processed is becoming available.
Abstract: Stereolithography is a solid freeform technique (SFF) that was introduced in the late 1980s Although many other techniques have been developed since then, stereolithography remains one of the most powerful and versatile of all SFF techniques It has the highest fabrication accuracy and an increasing number of materials that can be processed is becoming available In this paper we discuss the characteristic features of the stereolithography technique and compare it to other SFF techniques The biomedical applications of stereolithography are reviewed, as well as the biodegradable resin materials that have been developed for use with stereolithography Finally, an overview of the application of stereolithography in preparing porous structures for tissue engineering is given

319 citations

Journal ArticleDOI
TL;DR: The use of X-ray tomography has emerged as a uniquely powerful and non-destructive tool to analyze defects in additive manufacturing, such as unintended porosity, rough surfaces and deviations from design as mentioned in this paper.

308 citations

References
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Journal ArticleDOI
TL;DR: The state-of-the-art of additive manufacturing (AM) can be classified into three categories: direct digital manufacturing, free-form fabrication, or 3D printing as discussed by the authors.
Abstract: This paper reviews the state-of-the-art of an important, rapidly emerging, manufacturing technology that is alternatively called additive manufacturing (AM), direct digital manufacturing, free form fabrication, or 3D printing, etc. A broad contextual overview of metallic AM is provided. AM has the potential to revolutionize the global parts manufacturing and logistics landscape. It enables distributed manufacturing and the productions of parts-on-demand while offering the potential to reduce cost, energy consumption, and carbon footprint. This paper explores the material science, processes, and business consideration associated with achieving these performance gains. It is concluded that a paradigm shift is required in order to fully exploit AM potential.

4,055 citations

Book
01 Jan 2009
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.
Abstract: Additive Manufacturing Technologies: Rapid Prototyping to Direct Digital Manufacturing deals with various aspects of joining materials to form parts. Additive Manufacturing (AM) is an automated technique for direct conversion of 3D CAD data into physical objects using a variety of approaches. Manufacturers have been using these technologies in order to reduce development cycle times and get their products to the market quicker, more cost effectively, and with added value due to the incorporation of customizable features. Realizing the potential of AM applications, a large number of processes have been developed allowing the use of various materials ranging from plastics to metals for product development. Authors Ian Gibson, David W. Rosen and Brent Stucker explain these issues, as well as: Providing a comprehensive overview of AM technologies plus descriptions of support technologies like software systems and post-processing approaches Discussing the wide variety of new and emerging applications like micro-scale AM, medical applications, direct write electronics and Direct Digital Manufacturing of end-use components Introducing systematic solutions for process selection and design for AM Additive Manufacturing Technologies: Rapid Prototyping to Direct Digital Manufacturing is the perfect book for researchers, students, practicing engineers, entrepreneurs, and manufacturing industry professionals interested in additive manufacturing.

3,087 citations

Journal ArticleDOI
TL;DR: Additive manufacturing processes take the information from a computer-aided design (CAD) file that is later converted to a stereolithography (STL) file as discussed by the authors.
Abstract: Additive manufacturing processes take the information from a computer-aided design (CAD) file that is later converted to a stereolithography (STL) file. In this process, the drawing made in the CAD software is approximated by triangles and sliced containing the information of each layer that is going to be printed. There is a discussion of the relevant additive manufacturing processes and their applications. The aerospace industry employs them because of the possibility of manufacturing lighter structures to reduce weight. Additive manufacturing is transforming the practice of medicine and making work easier for architects. In 2004, the Society of Manufacturing Engineers did a classification of the various technologies and there are at least four additional significant technologies in 2012. Studies are reviewed which were about the strength of products made in additive manufacturing processes. However, there is still a lot of work and research to be accomplished before additive manufacturing technologies become standard in the manufacturing industry because not every commonly used manufacturing material can be handled. The accuracy needs improvement to eliminate the necessity of a finishing process. The continuous and increasing growth experienced since the early days and the successful results up to the present time allow for optimism that additive manufacturing has a significant place in the future of manufacturing.

1,777 citations

Journal ArticleDOI
TL;DR: Stereolithography is a solid freeform technique (SFF) that was introduced in the late 1980s as mentioned in this paper, and it has been widely used in biomedical applications, as well as the biodegradable resin materials developed for use with stereolithography.

1,760 citations

Journal ArticleDOI
TL;DR: In this paper, the effect of the recoil pressure and Marangoni convection in laser powder bed fusion (L-PBF) of 316L stainless steel was demonstrated. And the results were validated against the experiments and the sensitivity to laser absorptivity was discussed.

1,649 citations