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Additive Manufacturing, Materials, DFMA, Objectives to apply Additive…

- - - - Energy sources
        
        Laser
        
        Speed
        
        7m/s
        
        Focus
        
        100 micron
        
        PBF-EB/M Electron Beam
        
        Only materials whoch can conduct electricity
        
        Must be done in vacuum
        
        Advantage
        
        Can scan very fast
        
        12km/s? whaaaaaaaa
        
        requirement of "pre-sintering"
        
        Makes the insulative powder conductive
        
        avoids powder flying syndrome
        
        Powder Re-use
        
        Can be done to an extent
        
        sand blasted with same particles
        
        then sieved
        
        Use of supports
        
        Not required for residual stress removal/ done by pre-sintered bed
      - Scanning patterns
        
        Depth wise (z-direction)
        
        3-5 layers
        
        Reduces energy efficiency due to re-heating
        
        creating of meltpool
        
        behavior off meltpool?
        
        on X-Y plane
        
        Unidirectional
        
        Bi-directional
        
        Chess
        
        Old method, but still used
        
        67 degrees of rotation
        
        minimizes anisotropy
        
        why?
        
        Contour scan
        
        2-3 layer
        
        remelts to make the edges smoother
        
        Thermal gradient goes in one direction, leads to anisotropy
    - - Laser related parameters
        
        number of lasers
        
        when having multiple lasers, each laser has it's own zone where it works.
        
        laser Type
        
        Medium Energy (5-50W) IR Laser
      - Scan-related parameters
        
        scanning is never done // to air flow?
      - powder related parameters
        
        Non-uniform size distribution for efficient material filling
        
        Powder delivery system
      - Temperature-related parameters
        
        Design for residual stress?
        
        Design for temperature gradient?
    - - Always advised for metals
        
        Removes residual stress?
        
        Heat removal
        
        To have better dimensional stability
      - Polymers don't need supports
    - - Largest number of type of materials
      - Excellent material properties
      - No requirement of supports for polymers
    - - Poor manufacturing speed
  - - - PA12
      - PU
  - - - A lot of material waste
  - - - For biological material
        
        Chemical reaction
    - - Green part is made first
        
        Sintering makes it into a brown part.
  - - - Droplet deposition - Amazing Resolution
      - Could be really colorful
    - - <50nm
      - Melting temperature is decreased because of lack of bulk atoms
- - - - inclusions could be oxidation particles
- - - - restrictions
        
        Cost
        
        Material Handling
        
        very small particles can burn in air