A Design Modification Approach to Utilize the Benefits of Metal Additive Manufacturing Adoption

Abstract

Existing Metal Additive Manufacturing processes are fast approaching a matured stage in which a wide range of possibilities are available for the incorporation of the rapid fabrication technology to current industrial practices. In terms of design conventions, the limitless geometrical freedom allows complex structures including cellular internal grids and lattices to be formed without additional tooling. Repair parts and leveraging components can also be produced on demand when required especially for military assets where large volume of inventory is constantly maintained to ensure operational readiness. In this exemplary work, a feasibility study on using stainless steel material with integrated cellular design to manufacture a guide bracket found on a military vehicle via Selective Laser Melting process was conducted. The results showed appreciably better mechanical performance in using a stainless steel honeycomb as compared to the aluminum alloy used for the original component together with a faster production route through SLM.

Effective elastic moduli of metal honeycombs manufactured using selective laser melting

“…Redesigning bulk structures using cellular honeycombs require better understanding and predictable behavior, especially in the elastic region. This leads to a huge cut in the budget of aerospace industry for civil and defense sectors in the near future (Tan et al , 2016).…”