Precision Metal Additive Manufacturing

Additive manufacturing (AM) is a fast-growing sector with the ability to evoke a revolution in manufacturing due to its almost unlimited design freedom and its capability to produce personalised parts locally and with efficient material use. However,AM companies still face technological challenges such as limited precision due to shrinkage,built-in stresses and limited process stability and robustness. This book aims to inform the reader how to improve the precision of metal AM processes by tackling the three principles of robustness,predictability and metrology,and by developing computer-aided engineering methods that empower rather than limit AM design.

Format: Hardback
Length: 404 pages
Publication date: 22 September 2020
Publisher: Taylor & Francis Ltd

Additive manufacturing (AM) is a rapidly evolving sector with immense potential to transform the manufacturing industry due to its virtually limitless design freedom and the ability to produce customized parts locally, utilizing efficient materials. While AM companies have made significant advancements in recent years, they still encounter technological challenges such as limited precision due to shrinkage, built-in stresses, and limited process stability and robustness. Moreover, post-processing is often required to address high roughness and residual porosity. The availability of skilled and trained personnel is also a significant constraint.

Despite these challenges, significant progress has been made in AM design methods, process control, post-processing, material properties, and material range. However, for AM to achieve a substantial market share, it must evolve into a true precision manufacturing technique. The production of precision parts relies on three fundamental principles: robust production, predictable production, and measurable parts.

In the realm of metal AM, the process is inherently high-energy, involving numerous sensitive and interconnected process parameters, making it susceptible to thermal distortions, defects, and process drift. Fully modeling these complex processes is currently beyond the capabilities of current computational power, necessitating the development of novel methods to predict performance and inform design. Additionally, metal AM produces highly textured surfaces and intricate surface features that challenge the limitations of contemporary metrology.

Given the multitude of factors involved, there is a significant lack of comprehensive background material on AM, particularly in metals. This lack of information hinders the widespread adoption and optimization of AM technologies in various industries. To address these challenges, researchers, industry experts, and policymakers need to collaborate to promote AM research, development, and training. This will enable the industry to fully harness the potential of AM and drive innovation in manufacturing.

In conclusion, additive manufacturing (AM) is a rapidly growing sector with the potential to revolutionize manufacturing through its design freedom, local production capabilities, and efficient material utilization. While AM companies have made significant progress, they still face technological challenges and a shortage of skilled personnel. By embracing precision manufacturing principles, developing novel methods, and promoting collaboration, AM can evolve into a true game-changer in the manufacturing industry.

Weight: 942g
Dimension: 184 x 261 x 28 (mm)
ISBN-13: 9781138347717