I found the book to be of exceptional quality. The topics are coherently and overarchingly discussed right from the basics of laser powder bed fusion to its physics and modelling, porosity defects, residual stresses, non-destructive characterisation, process monitoring, lattice materials, metamaterials, mechanical properties, novel material developments and future trends. Altogether there are 24 chapters, each authored by respective leaders in the field totalling 58 authors from around the globe. The book concludes with an interesting case study that puts some of the key aspects into perspective.Overall, this is the most comprehensive book regarding laser powdered bed fusion of metals to date. As such it is a recommended reading for undergraduates, postgraduates, researchers, and advanced practitioners in the field of metal additive manufacturing. The book is suitable both for guided learning and quick reference.
Additive manufacturing (AM) is the process of creating a three-dimensional object from a digital file. It is called additive because it generally involves building up thin layers of material, one by one. The technology can produce complex shapes that are not possible with traditional casting, machining, or subtractive techniques.
Generative design software brought new dimensions to additive manufacturing. Using the software, generative design tools were able to create shapes that would not be possible with traditional manufacturing processes. The geometric flexibility allows designers to access an entirely new design landscape using software tools that utilize artificial intelligence to iterate parts.
Using generative design tools, engineers can outline where a part should exist, what forces are acting upon it, and delineate areas to avoid. The computer does the rest. As well as changing how metal parts are produced, additive manufacturing can produce cleaner parts by using sustainable manufacturing processes.
By making it easy to create lightweight parts for everything from cars to airplanes, additive manufacturing not only uses less raw materials but can help lower fuel use, resulting in lower carbon emissions. While there has been a huge growth in metal AM, the industry is still in its infancy when it comes to manufacturing production parts.
Additive manufacturing is causing fundamental changes in the way parts are produced. Where typical manufacturing operates by cutting away or molding material, in additive manufacturing, digital designs guide the fabrication of complex, three-dimensional products that are built up, layer by layer.
The Material Measurement Laboratory is investigating additive manufacturing-related issues for both metals and polymers. Projects underway include studying the fracture and fatigue properties of additive manufacturing materials, nano-mechanical properties of surfaces and flaws in these materials, modeling of microstructure evolution, and relationships between precursor material and final product quality.
The Physical Measurement Laboratory is studying emissive properties of materials in solid, powder, and liquid states, as well as improved techniques for real-time temperature measurements to support better understanding and modeling of additive manufacturing processes.
Individuals may pursue Additive Manufacturing Certification at the Fundamentals or Technician level, depending on their knowledge and experience. These certifications create a flexible, modular pathway for mastering the principles and processes of additive manufacturing.
The Fundamentals exam focuses on the basics of additive manufacturing, including a comprehensive overview of additive manufacturing, the seven additive manufacturing technologies, and basic safety guidelines.
The Fundamentals certification is ideal for individuals working in or seeking to work in additive manufacturing roles in automotive, aerospace, and medical equipment. It is also ideal for high schools and colleges as a capstone or stand-alone achievement to increase workforce readiness in additive manufacturing.
The Technician exam focuses on the methodology of additive manufacturing, including the seven additive manufacturing technologies, processes, material selection, post-processing, and basic safety guidelines.
Companies looking to cross-train, onboard or just further educate and enhance the skills of their engineering and manufacturing workforce in additive manufacturing should read more about our comprehensive portfolio of additive manufacturing solutions. Visit Tooling U-SME, the workforce development division of SME.
High schools and colleges interested in providing training in additive manufacturing and/or offering the exam for the certification in additive manufacturing for students should read more about our comprehensive portfolio of additive manufacturing solutions. Visit Tooling U-SME, the workforce development division of SME.
This paper aims to help companies working in highly regulated industries ascertain what to look for in an additive manufacturing feedstock supplier and how to help their current supply chain mature.
We focus on the four main pillars that serve as the foundation that allows the metal additive manufacturing raw material supply chain to mature within highly regulated industries, particularly the medical and aerospace device industries;
In 2017 the first high-power industrial blue laser reached the market. It rapidly demonstrated unmatched speed and quality for welding copper, aluminum, and many other industrially important materials. The same fundamental physical characteristics needed for welding reflective metals also suit additive manufacturing.
Additive manufacturing for metalsAdditive manufacturing / 3D printing started as a method to quickly produce prototype parts to check form, fit, and function. Many early 3D printers used photo resins to create a desired part.
The technology matured to offer a handful of different fabrication styles for a wider range of materials. For additive manufacturing of metals, two approaches dominate: powder bed fusion (PBF), covering about 95% of applications, and laser metal deposition (LMD), generally for larger parts. Although alternative methods of energy deposition are available, lasers are the most flexible and straightforward mechanism.
For fabricating to design dimensions, additive manufacturing often requires support elements that must be machined away, and the incremental addition of material leads to surfaces that usually require at least some degree of grinding and polishing. The goal is to reduce those post-fabrication operations to a minimum, that is, to achieve a near net-to-shape part.
The blue laser is a relatively new entrant into the additive manufacturing arena, and, as such, work has just begun to determine the optimum process parameters. Even at this early stage, the blue laser matches the high expectations set by its performance in welding. As seen in Table 1 and described below (see sidebar: Building blocks of blue performance), the blue laser produces parts at rates comparable to or significantly faster than the incumbent IR technology, with improved quality. But quality is only part of the story. Any new technology must not only demonstrate its capability, but also show its readiness to step into a manufacturing environment, where stability and reliability are essential.
Stability and reliabilityAlthough the blue laser is relatively new to the additive manufacturing world, it benefits from its previous deployments in factory environments. The blue laser is used for welding in battery fabrication, consumer electronics production, and electric vehicle manufacturing. From its inception, the blue industrial laser was designed specifically with the robustness necessary to provide reliable, stable operation in challenging production environments.
The fundamental physical advantage has already brought benefits to a variety of industries, including energy storage, consumer electronics, and e-mobility, where the process improvements have led to production efficiencies and higher product quality. Now, that proven advantage is being turned to applications in additive manufacturing.
MSE 310 Introduction to Materials Science and Engineering (3)Introduces the materials field to new department majors. Examples are drawn from ceramics, metals, polymers, electronic materials, and composites. Structure-properties-manufacturing-design relationships are emphasized. Materials selection design project. Introduction to research. Offered: A.View course details in MyPlan: MSE 310
MSE 489 Additive Manufacturing: Materials, Processing and Applications (3)Additive manufacturing processes for polymers, metals, ceramics and composite materials. Operating principles, key process parameters important to the part build process, and the importance of design. Microstructure of the build parts, dependence on processing conditions, the mechanical and physical properties, defects and relevant post-processing treatments for each material system. Hybrid processes, and adoption in various fields. Offered: jointly with M E 402; Sp.View course details in MyPlan: MSE 489
MSE 490 Composite Materials in Manufacturing (3)Manufacturing processes for composite materials, with a focus on thermosets. Composite manufacturing process from raw materials manufacturing to shipping final products. Controlling parameters leading to defects. Balance between design and quality system manufacturing controls, relationship of process development to engineering design, and procedures for materials and process changes. Identification and repair of manufacturing anomalies. Offered: Sp.View course details in MyPlan: MSE 490
MSE 589 Additive Manufacturing: Materials, Processing and Applications (3)Additive manufacturing processes for polymers, metals, ceramics and composite materials. Operating principles, key process parameters important to the part build process, and the importance of design. Microstructure of the build parts, dependence on processing conditions, the mechanical and physical properties, defects and relevant post-processing treatments for each material system. Hybrid processes, and adoption in various fields. Offered: jointly with M E 506; Sp.View course details in MyPlan: MSE 589 59ce067264