Nowadays, due to rapid prototyping processes improvements, a functional metal part can be built directly by Additive Manufacturing. It is now accepted that these new processes can increase productivity while enabling a mass and cost reduction and an increase of the parts functionality. However, the physical phenomena that occur during these processes have a strong impact on the quality of the produced parts. Especially, because the manufacturing paths used to produce the parts lead these physical phenomena,

Cleaner production and sustainability are of crucial importance in the field of manufacturing processes where great amounts of energy and materials are being consumed. Nowadays, additive manufacturing technologies such as Direct Additive Laser Manufacturing allow us to manufacture functional products with high added value. Insofar as environmental considerations become an important issue in our society, as well as legislation regarding environment become prominent (Normalization ISO 14 044), the environmental impact of those processes have to be evaluated in order to make easier its acceptance in the industrial world. Some studies have been conducted on electric consumption of machine tools (stand-by consumption, in process consumption, etc) but only a few studies take into account the whole existing environmental flows (material, fluids, electricity). This paper presents a new methodology where all flows consumed (material, fluids, electricity) are considered in the environmental impact assessment. This method coupled a global view required in a sustainable approach and an accurate evaluation of flows consumption in the machine. The methodology developed is based on a predictive model of flows consumption defined from the manufacturing path and CAD model of the part which will be produce. In order to get an accurate model of the process, each feature of the machine is modeled. The goal of this work is to integrate this model into the design loop for additive manufacturing parts.

Integration of the Rapid Prototyping environmental aspects: first focus on the electrical energy consumption. Design/methodology/approach Various manufacturing parameters have been tested on three rapid prototyping systems: Thermojet (3DS), FDM 3000 (Stratasys) and EOSINT M250 Xtended (EOS). The objective is to select sets of parameters for reduction of electrical energy consumption. For this, we have manufactured a part in several orientations and positions in the chamber of these RP systems. For each test, we noted the electrical power. Finally, we propose certain rules to minimize this electrical energy consumption during a job. Findings It is important to minimize the manufacturing time but there is no general rule for optimization of electrical energy consumption. Each RP system must be tested with energy consumption considerations under the spotlight. Research limitations/implications Our work is only based on Rapid Prototyping processes. Our objective is to take into consideration the complete life-cycle of an rapid prototyped part: manufacturing of raw material as far as reprocessing of waste. Practical implications To decrease electrical energy consumption for a job What is original/value of paper The environmental aspects are not studied as well as in rapid prototyping.

International audienceAdditive Manufacturing is an innovative way to produce parts. However its environmental impact is unknown. To ensure the development of additive manufacturing processes it seems important to develop the concept of DFSAM (Design for Sustainable Additive Manufacturing). In fact, one of the objectives of environmental sustainable manufacturing is to minimize the whole flux consumption (electricity, material and fluids) during manufacturing step. To achieve this goal, it is interesting to get a predictive model of consumptions, integrated in the design step, allowing to evaluate the product's environmental impact during the manufacturing step. This paper presents a new methodology for electric, fluids and raw material consumptions assessment for additive manufacturing processes, in particular for a direct metal deposition process. The methodology will help engineers to design parts optimized for additive manufacturing with an environmental point of view

Design For Manufacturing (DFM) approaches aim to integrate manufacturability aspects during the design stage. Most of DFM approaches usually consider only one manufacturing process, but products competitiveness may be improved by designing hybrid modular products, in which products are seen as 3-D puzzles with modules realized aside by the best manufacturing process and further gathered. A new DFM system is created in order to give quantitative information during the product design stage of which modules will benefit in being machined and which ones will advantageously be realized by an additive process (such as Selective Laser Sintering or laser deposition). A methodology for a manufacturability evaluation in case of a subtractive or an additive manufacturing process is developed and implemented in a CAD software. Tests are carried out on industrial products from automotive industry

International audienceThe additive laser manufacturing (ALM) technique is an additive manufacturing process which enables the rapid manufacturing of complex metallic parts and the creation of thin parts so as, for example, to decrease parts weight for biomechanical or aeronautic applications. Furthermore, compared with selective laser sintering technology, the ALM process allows creating more huge parts and material gradient. However, for aesthetic or tribological functions, the ALM surfaces need an additional finishing operation, such as the polishing operation. Polishing processes are usually based on abrasive or chemical techniques. These conventional processes are composed by many drawbacks such as accessibility of complex shape, environmental impact, high time consumption and cost, and health risks for operators. In order to solve these problems and to improve surface quality, the laser polishing (LP) process is investigated. Based on melting material by laser, laser polishing process enables the smoothing of initial topography. However, the ALM process and the laser polishing processes are based on laser technology. In this context, the laser ALM process is used directly on the same machine for the polishing operation. Moreover, an alternation between both processes can be established during the manufacturing operation in order to treat nonaccessible surfaces. Currently, few studies focus on laser polishing of additive laser manufacturing surfaces, and it tends to limit the industrial use of additive manufacturing technology. The proposed study describes an experimental investigation of laser polishing surfaces obtained by additive laser manufacturing process. The investigation results in the improvement of complete final surface quality, according to laser polishing parameters. This experimental study introduces the laser polishing of thin section parts, in order to develop laser polishing applications. According to a manufacturing chain context, the final objective is to create a multiprocess mastery in order to optimize the final topography and productivity time

No abstract

International audienceNowadays, due to rapid prototyping processes improvements, a functional part can be built directly through additive manufacturing. It is now accepted that these new processes can increase productivity while enabling a mass and cost reduction and an increase of the parts functionality. However, in order to achieve this, new design methods have to be developed to take into account the specificities of these processes, with the Design For Additive Manufacturing (DFAM) concept. In this context, a methodology to obtain a suitable design of parts built through additive manufacturing is proposed ; both design requirements and manufacturing constraints are taken into account