Digitalization of design for support structures in laser powder bed fusion of metals

Additive manufacturing is a key technology for digital production, but barriers exist. This thesis develops a digital, automated support structure design procedure using topology optimization and space colonization algorithm, proven experimentally to achieve sufficient mechanical performance and cost reduction at medium to large production scales.

Format: Paperback / softback
Length: 300 pages
Publication date: 19 February 2023
Publisher: Springer International Publishing AG

Additive manufacturing (AM) is widely recognized as a vital technology for digital production, offering significant advantages in terms of efficiency, customization, and rapid prototyping. However, despite its potential, the widespread industrial adoption of AM has been hindered by several barriers. These include the high cost associated with AM equipment and the specialized expertise required to operate and maintain them.
To overcome these challenges, the complete digitalization of the value creation process is essential. This thesis proposes a digital, automated support structure design procedure that utilizes topology optimization for design rule determination and adapts the space colonization algorithm for automated design. The validity of the proposed procedure is demonstrated through experimental validation, showcasing excellent mechanical performance alongside significant cost reductions at medium to large production scales.

The cost of AM equipment is a significant barrier to its industrial adoption. Traditional manufacturing methods, such as subtractive machining, involve the removal of material from a solid block, which can be more cost-effective for large-scale production. However, AM requires the use of 3D printers, which can be expensive to purchase and maintain. The cost of materials used in AM can also be higher than traditional manufacturing methods, as AM requires specialized materials such as plastics, metals, and ceramics.
In addition to the cost of equipment, the expertise required to operate and maintain AM equipment is another barrier to industrial adoption. AM requires skilled technicians who can program and control 3D printers, as well as understand the underlying principles of AM. This expertise is not widely available, and training programs for AM technicians can be expensive and time-consuming.
To address these barriers, the complete digitalization of the value creation process is necessary. This involves the integration of AM equipment into existing manufacturing systems, as well as the development of new software and technologies that can automate the design and production of AM parts. This will enable manufacturers to reduce the cost of AM equipment and the expertise required to operate it, making AM more accessible to a wider range of industries.
One approach to achieving this digitalization is through the use of automation. Automation can reduce the cost of AM equipment and the expertise required to operate it by automating the design and production processes. For example, automated 3D printing systems can be used to produce AM parts without the need for skilled technicians. This can reduce the cost of AM equipment and the time required to produce parts, making AM more competitive with traditional manufacturing methods.
Another approach to achieving this digitalization is through the use of software. Software can be used to automate the design and production processes of AM, as well as to optimize the design of AM parts. For example, software can be used to optimize the shape and size of AM parts to reduce material waste and improve the mechanical performance of the parts. This can help manufacturers to reduce the cost of AM equipment and the time required to produce parts, making AM more competitive with traditional manufacturing methods.
In addition to the use of automation and software, the complete digitalization of the value creation process also involves the development of new materials and technologies. New materials and technologies can be used to improve the performance of AM parts, as well as to reduce the cost of AM equipment and the expertise required to operate it. For example, new materials such as biodegradable plastics and metals can be used to reduce the environmental impact of AM, while new technologies such as 3D printing with metal powder can be used to produce AM parts with higher strength and durability.
To achieve the complete digitalization of the value creation process, it is essential to collaborate across industries and academia. This involves the sharing of knowledge and expertise, as well as the development of new standards and regulations that can promote the adoption of AM. For example, industry associations.
In conclusion, additive manufacturing is considered a key technology for digital production, offering significant advantages in terms of efficiency, customization, and rapid prototyping. However, the widespread industrial adoption of AM has been hindered by several barriers, including the high cost associated with AM equipment and the specialized expertise required to operate and maintain them. To overcome these challenges, the complete digitalization of the value creation process is essential. This thesis proposes a digital, automated support structure design procedure that utilizes topology optimization for design determination and adapts the space colonization algorithm
algorithm for automated design. The validity of the proposed procedure is demonstrated through experimental validation, showcasing excellent mechanical performance alongside significant cost reductions at medium to large production scales.

The cost of AM equipment is a significant barrier to its industrial adoption. Traditional manufacturing methods, such as subtractive machining, involve the removal of material from a solid block, which can be more cost-effective for large-scale production. However, AM requires the use of 3D printers, which can be expensive to purchase and maintain. The cost of materials used in AM can also be higher than traditional manufacturing methods, as AM requires specialized materials such as plastics, metals, and ceramics.
In addition to the cost of equipment, the expertise required to operate and maintain AM equipment is another barrier to industrial adoption. AM requires skilled technicians who can program and control 3D printers, as well as understand the underlying principles of AM. This expertise is not widely available, and training programs for AM technicians can be expensive and time-consuming.
To address these barriers, the complete digitalization of the value creation process is necessary. This involves the integration of AM equipment into existing manufacturing systems, as well as the development of new software and technologies that can automate the design and production of AM parts. This will enable manufacturers to reduce the cost of AM equipment and the expertise required to operate it, making AM more accessible to a wider range of industries.
One approach to achieving this digitalization is through the use of automation. Automation can reduce the cost of AM equipment and the expertise required to operate it by autom. For example, automated 3D printing systems can be used to produce AM parts without the need for skilled technicians. This can reduce the cost of AM equipment and the time required to produce parts, making AM more competitive with traditional manufacturing methods.
Another approach to achieving this digitalization is through the use of software. Software can be used to automate the design and production processes of AM, as well as to optimize the design of AM parts. For example, software can be used to optimize the shape and size of AM parts to reduce material waste and improve the mechanical performance of the parts. This can help manufacturers to reduce the cost of AM equipment and the time required to produce parts, making AM more competitive with traditional manufacturing methods.
In addition to the use of automation and software, the complete digitalization of the value creation process also involves the development of new materials and technologies. New materials and technologies can be used to improve the performance of AM parts, as well as to reduce the cost of AM equipment and the expertise required to operate it. For example, new materials such as biodegradable plastics and metals can be used to reduce the environmental impact of AM, while new technologies such as 3D printing with metal powder can be used to produce AM parts with higher strength and durability.
To achieve the complete digitalization of the value creation process, it is essential to collaborate across industries and academia. This involves the sharing of knowledge and expertise, as well as the development of new standards and regulations that can promote the adoption of AM. For example, industry.
In conclusion, additive manufacturing is considered a key technology for digital production, offering significant advantages in terms of efficiency, customization, and rapid prototyping. However, the widespread industrial adoption of AM has been hindered by several barriers, including the high cost associated with AM equipment and the specialized expertise required to operate and maintain them. To overcome these challenges, the complete digitalization of the value creation process is essential. This thesis proposes a digital, automated support structure design procedure that utilizes topology optimization for design determination and adapts the space colonization algorithm. The validity of the proposed procedure is demonstrated through experimental validation, showcasing excellent mechanical performance alongside significant cost reductions at medium to large production scales.

Weight: 571g
Dimension: 240 x 168 (mm)
ISBN-13: 9783031229558
Edition number: 1st ed. 2023