Advanced lattice support structures for metal additive manufacturing

Hussein, Ahmed Yussuf; Hao, Liang; Yan, Chunze; Everson, Richard; Young, Paul A.

doi:10.1016/j.jmatprotec.2013.01.020

Cited by 368 publications

(150 citation statements)

References 8 publications

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“…Most of the studies typically discussed in literature searches discuss rule-of-thumb ways to physically prevent the stresses from destroying the parts during printing and are little concerned with trying to understand the mechanics of the stresses and how they directly affect the overhanging features. There was considerable discussion of this problem in the studies by Hussein et al [21,22], Matsumoto et al [18], Calingnano [23], Mohanty and Hattel [24], Zeng [25], Li et al [26] and Gan and Wong [27], but these addressed application-specific issues and did not discuss the problem at the level of feature and part design. Some of the opinions commonly heard from practitioners are that the overhanging features are most severely affected by the stresses because they are not physically welded to the build plate during the printing and are thinner and less resistant to thermal shock.…”

Section: The Slm/dmls Residual Stresses Problemmentioning

confidence: 99%

“…Some studies that discuss the pros and cons of support structures to prevent damage in SLM/DMLS well were those performed by Hussein et al [21,22], Jhabvala et al [28], Matsumoto et al [18], Thomas and Bibb [29,30], Wang et al [31], Kruth et al [32] and Papadakis et al [33]. Data from several studies by Hussein et al [22], Kruth et al [32], Vora et al [34] and Patterson et al [35,36] suggested that the use of rigid support structures during SLM/DMLS for overhanging features may actually cause the residual stresses to be worse than if the overhang had no solid support during printing.…”

Section: The Slm/dmls Residual Stresses Problemmentioning

confidence: 99%

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Overhanging Features and the SLM/DMLS Residual Stresses Problem: Review and Future Research Need

2017

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Abstract:A useful and increasingly common additive manufacturing (AM) process is the selective laser melting (SLM) or direct metal laser sintering (DMLS) process. SLM/DMLS can produce full-density metal parts from difficult materials, but it tends to suffer from severe residual stresses introduced during processing. This limits the usefulness and applicability of the process, particularly in the fabrication of parts with delicate overhanging and protruding features. The purpose of this study was to examine the current insight and progress made toward understanding and eliminating the problem in overhanging and protruding structures. To accomplish this, a survey of the literature was undertaken, focusing on process modeling (general, heat transfer, stress and distortion and material models), direct process control (input and environmental control, hardware-in-the-loop monitoring, parameter optimization and post-processing), experiment development (methods for evaluation, optical and mechanical process monitoring, imaging and design-of-experiments), support structure optimization and overhang feature design; approximately 143 published works were examined. The major findings of this study were that a small minority of the literature on SLM/DMLS deals explicitly with the overhanging stress problem, but some fundamental work has been done on the problem. Implications, needs and potential future research directions are discussed in-depth in light of the present review.

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Section: The Slm/dmls Residual Stresses Problemmentioning

confidence: 99%

Section: The Slm/dmls Residual Stresses Problemmentioning

confidence: 99%

Overhanging Features and the SLM/DMLS Residual Stresses Problem: Review and Future Research Need

2017

View full text Add to dashboard Cite

show abstract

“…Most of the studies typically discussed in literature searches discuss rule-of-thumb ways to physically prevent the stresses from destroying the parts during printing and are little concerned with trying to understand the mechanics of the stresses and how they directly affect the overhanging features. There was considerable discussion of this problem in the studies by Hussein et al [21][22] Some of the opinions commonly heard from practitioners are that the overhanging features are most severely affected by the stresses because they are not physically welded to the build plate during the printing and are thinner and less resistant to thermal shock. Depending on the specific geometry, stress concentrations between the features and the main parts also likely play a role in magnifying the effect.…”

Section: Figure 1 Slm/dmls Process Mechanicsmentioning

confidence: 99%

“…Some studies that well discuss the pros and cons of support structures to prevent damage in SLM/DMLS were those performed by Hussein et al [21][22] [34] and Patterson et al [35][36] suggested that the use of rigid support structures during SLM/DMLS for overhanging features may actually cause the residual stresses to be worse than if the overhang had no solid support during printing.…”

Section: Figure 1 Slm/dmls Process Mechanicsmentioning

confidence: 99%

“…Hussein et al [21][22], Maliaris et al [132], Strano et al [133]. Sundar et al found that printing the part on top of a wire mesh made removal from the build plate easier, facilitated the creation of delicate features and thin walls, reduced the time needed to cut off the support structure, and created a buffer to prevent damage to the part itself from the removal.…”

Section: Support Structure Optimizationmentioning

confidence: 99%

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Overhanging Features and the SLM/DMLS Residual Stresses Problem: Review and Future Research Need

Patterson¹,

Messimer²,

Farrington³

2017

Preprint

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A useful and increasingly common additive manufacturing (AM) process is the selective laser melting (SLM) or direct metal laser sintering (DMLS) process. SLM/DMLS can produce fulldensity metal parts from difficult materials, but it tends to suffer from severe residual stresses introduced during processing. This limits the usefulness and applicability of the process, particularly in the fabrication of parts with delicate overhanging and protruding features. The purpose of this study was to examine the current insight and progress made toward understanding and eliminating the problem in overhanging and protruding structures. To accomplish this, a survey of literature was undertaken, focusing on process modeling (general, heat transfer, stress and distortion, and material models), direct process control (input and environmental control, hardware-in-the-loop monitoring, parameter optimization, and post-processing), experiment development (methods for evaluation, optical and mechanical process monitoring, imaging, and design-of-experiments), support structure optimization, and overhang feature design; approximately 140 published works were examined. The major findings of this study were that a small minority of the literature on SLM/DMLS deals explicitly with the overhanging stress problem, but some fundamental work has been done on the problem. Implications, needs, and potential future research directions are discussed in-depth in light of the present review.

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Design for Metal Additive Manufacturing

2021

Metal Additive Manufacturing

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Advanced lattice support structures for metal additive manufacturing

Cited by 368 publications

References 8 publications

Overhanging Features and the SLM/DMLS Residual Stresses Problem: Review and Future Research Need

Overhanging Features and the SLM/DMLS Residual Stresses Problem: Review and Future Research Need

Overhanging Features and the SLM/DMLS Residual Stresses Problem: Review and Future Research Need

Design for Metal Additive Manufacturing

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