A review of technological improvements in laser-based powder bed fusion of metal printers

Khorasani, Amir Mahyar; Gibson, Ian; Veetil, Jithin Kozhuthala; Ghasemi, Arman

doi:10.1007/s00170-020-05361-3

Cited by 137 publications

(54 citation statements)

References 47 publications

(52 reference statements)

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“…The development of L-PBF machines has led to higher production capacity. Simultaneous processing with multiple high power lasers in the work area, high-speed scanners, and an adjustable layer thickness increase the throughput [41,68,76,77]. Use of the simulation driven DfAM software adds value to creation, optimization, and simulation analysis of designs before actual manufacturing.…”

Section: Resultsmentioning

confidence: 99%

Integration of Simulation Driven DfAM and LCC Analysis for Decision Making in L-PBF

Nyamekye

Unt

Salminen

et al. 2020

Metals

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Laser based powder bed fusion (L-PBF) is used to manufacture parts layer by layer with the energy of laser beam. The use of L-PBF for building functional parts originates from the design freedom, flexibility, customizability, and energy efficiency of products applied in dynamic application fields such as aerospace and automotive. There are challenges and drawbacks that need to be defined and overcome before its adaptation next to rivaling traditional manufacturing methods. Factors such as high cost of L-PBF machines, metal powder, post-preprocessing, and low productivity may deter its acceptance as a mainstream manufacturing technique. Understanding the key cost drivers of L-PBF that influence productivity throughout the whole lifespan of products will facilitate the decision-making process. Functional and operational decisions can yield profitability and increase competitiveness among advanced manufacturing sectors. Identifying the relationships between the phases of the life cycle of products influences cost-effectiveness. The aim of the study is to investigate the life cycle cost (LCC) and the impact of design to it in additive manufacturing (AM) with L-PBF. The article provides a review of simulation driven design for additive manufacturing (simulation driven DfAM) and LCC for metallic L-PBF processes and examines the state of the art to outline the merits, demerits, design rules, and life cycle models of L-PBF. Practical case studies of L-PBF are discussed and analysis of the interrelating factors of the different life phases are presented. This study shows that simulation driven DfAM in the design phase increases the productivity throughout the whole production and life span of L-PBF parts. The LCC model covers the whole holistic lifecycle engineering of products and offers guidelines for decision making.

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Section: Resultsmentioning

confidence: 99%

Integration of Simulation Driven DfAM and LCC Analysis for Decision Making in L-PBF

Nyamekye

Unt

Salminen

et al. 2020

Metals

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“…For example, to keep a minimum of two contiguous cells along the intravertebral height of ~5 mm [ 58 , 59 ], a unitary gyroid cell cannot be bigger than 2.5 mm (2500 μm), which results in a porosity of 60%. At an upper level of 80%, the minimal sheet thickness of ~100 µm of the gyroid structures is close to the manufacturing limits of most laser powder bed fusion (LPBF) additive manufacturing systems [ 60 ]. The middle value of 70% is selected to provide a minimum of three data points for the generation of scaling relations.…”

Section: Methodsmentioning

confidence: 99%

Mechanical properties and fluid permeability of gyroid and diamond lattice structures for intervertebral devices: functional requirements and comparative analysis

Timercan

Sheremetyev

Braïlovski

2021

Science and Technology of Advanced Materials

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Current intervertebral fusion devices present multiple complication risks such as a lack of fixation, device migration and subsidence. An emerging solution to these problems is the use of additively manufactured lattice structures that are mechanically compliant and permeable to fluids, thus promoting osseointegration and reducing complication risks. Strut-based diamond and sheet-based gyroid lattice configurations having a pore diameter of 750 µm and levels of porosity of 60, 70 and 80% are designed and manufactured from Ti-6Al-4V alloy using laser powder bed fusion. The resulting structures are CT–scanned, compression tested and subjected to fluid permeability evaluation. The stiffness of both structures (1.9–4.8 GPa) is comparable to that of bone, while their mechanical resistance (52–160 MPa) is greater than that of vertebrae (3–6 MPa), thus decreasing the risks of wither bone or implant failure. The fluid permeability (5–57 × 10 −9 m 2 ) and surface-to-volume ratios (~3) of both lattice structures are close to those of vertebrae. This study shows that both types of lattice structures can be produced to suit the application specifications within certain limits imposed by physical and equipment-related constraints, providing potential solutions for reducing the complication rate of spinal devices by offering a better fixation through osseointegration.

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“…Compared with other metallic AM techniques, laser powder bed fusion (LPBF) is well-suited for fabricating the TPMS structures with high resolution and good dimensional accuracy [ 2 ]. Generally, most LPBF machines hold a typical accuracy of ±50 μm [ 14 ] and a minimum feature size of 200 μm [ 15 ]. The printed components with TWS feature design always show an increase in the relative density as the adjacent powder melts and sticks to the surface [ 16 ].…”

Section: Introductionmentioning

confidence: 99%

Achieving Triply Periodic Minimal Surface Thin-Walled Structures by Micro Laser Powder Bed Fusion Process

Ding

Song

2021

Micromachines

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Recently, triply periodic minimal surface (TPMS) lattice structures have been increasingly employed in many applications, such as lightweighting and heat transfer, and they are enabled by the maturation of additive manufacturing technology, i.e., laser powder bed fusion (LPBF). When the shell-based TPMS structure’s thickness decreases, higher porosity and a larger surface-to-volume ratio can be achieved, which results in an improvement in the properties of the lattice structures. Micro LPBF, which combines finer laser beam, smaller powder, and thinner powder layer, is employed in this work to fabricate the thin-walled structures (TWS) of TPMS lattice by stainless steel 316 L (SS316L). Utilizing this system, the optimal parameters for printing TPMS-TWS are explored in terms of densification, smoothness, limitation of thickness, and dimensional accuracy. Cube samples with 99.7% relative density and a roughness value of 2.1 μm are printed by using the energy density of 100 J/mm3. Moreover, a thin (100 μm thickness) wall structure can be fabricated through optimizing parameters. Finally, the TWS samples with various TPMS structures are manufactured to compare their heat dissipation capability. As a result, TWS sample of TPMS lattice exhibits a larger temperature gradient in the vertical direction compared to the benchmark sample. The steady-state temperature of the sample base presents a 7 K decrease via introducing TWS.

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A review of technological improvements in laser-based powder bed fusion of metal printers

Cited by 137 publications

References 47 publications

Integration of Simulation Driven DfAM and LCC Analysis for Decision Making in L-PBF

Integration of Simulation Driven DfAM and LCC Analysis for Decision Making in L-PBF

Mechanical properties and fluid permeability of gyroid and diamond lattice structures for intervertebral devices: functional requirements and comparative analysis

Achieving Triply Periodic Minimal Surface Thin-Walled Structures by Micro Laser Powder Bed Fusion Process

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